Volkswagen Touareg 2004-06

Brake Caliper

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions in the beginning of this Section.
  2.  
  3. Raise the vehicle and remove the wheels.
  4.  
  5. Press the retaining spring in until it can be pressed out of the bore.
  6.  
  7. Turn the retaining spring clockwise until it can be removed from the upper bore.
  8.  
  9. Unplug the connector for the brake pad wear indicator.
  10.  
  11. Remove the dust cap and lift off the wire for the brake pad wear indicator.
  12.  
  13. Remove the brake pad wear indicator wire from the retainer on the caliper.
  14.  
  15. Attach the hose from a bleeder bottle onto the valve of the brake caliper and then open the bleeder valve.
  16.  
  17. Lightly preload the brake pedal using tool V.A.G 1869/2 or equivalent.
  18.  
  19. Close the bleeder valve and remove bleeder bottle.
  20.  
  21. Disconnect and plug the brake line.
  22.  
  23. Remove the caps, then remove both guide pins from the brake caliper.
  24.  
  25. Remove the brake caliper from the carrier.
  26.  
  27. If necessary, remove the brake pads from the caliper.
  28.  

To install:

  1. Push the piston back in its bore with piston resetting tool T10145-1 or equivalent.
  2.  
  3. If removed, install the brake pads.
  4.  
  5. Attach the brake caliper to the carrier with the guide pins. Install both caps.
  6.  
  7. Connect the brake line to the brake caliper.
  8.  
  9. Remove the brake pedal preloading tool.
  10.  
  11. Install the retaining spring into the upper bore and turn it downwards.
  12.  
  13. Set the retaining spring on the bottom of the carrier.
  14.  
  15. First press the retaining spring in, then at the same time into the bore of brake caliper.
  16.  
  17. The remaining installation is the reverse of removal. Bleed the brake system and check the brake fluid level. Observe the following torque specifications:
    NOTE
    Depress the brake pedal firmly several times with vehicle stationary so that the brake pads are properly seated in their normal operating position.



    Guide pins to carrier: 22 ft. lbs. (30 Nm)
     
    Front brake line to brake caliper: 10 ft. lbs. (14 Nm)
     
    Rear brake line banjo fitting bolt: 28 ft. lbs. (38 Nm)
     



    Click image to see an enlarged view

    Fig. Exploded view of the brake assembly

  18.  

 
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