Volkswagen Tiguan Service and Repair Manual: Rear Brake Caliper, Servicing

Overview - Brake Caliper CII 41

• Install the entire repair kit when servicing.
• Only use mineral spirits to clean the brakes.
• New brake calipers are filled with brake fluid and are pre-bled.
• Apply a thin coat of Assembly Paste -G 052 150 A2- to brake cylinders, pistons and seals.
• If a repair is required, the brake calipers must always be pre-bled before being installed in the vehicle (without brake pads).

1. Brake Caliper
   • Pre-bleed the brake caliper after servicing
2. Self-Locking Bolt
   • 35 Nm
   • Replacing
   • When loosening and tightening, counterhold at guide pin
3. Dust Cap
4. Bleeder Valve
   • 10 Nm
   • Apply a thin coat of Assembly Paste -G 052 150 A2- to the threads before screwing in.
5. TORX Socket Bolt
   • 12 Nm
6. Parking Brake Motor
7. Seal
8. Guide Pin
   • Grease before pulling on the protective cap
9. Protective Cap
   • Install on brake carrier and guide pin.
10. Brake Carrier with Guide Pins and Protective Cap
    • Delivered as an assembled replacement part with sufficient grease on the guide pins
    • Install the repair kit if the caps or guide pins are damaged. Use the supplied grease packet to lubricate guide pins.
11. Protective Cap
    • Pull onto the piston with the outer sealing lip
    • Removing and installing.
    • Pull onto the piston with the outer sealing lip
    • Removing and installing.
12. Piston
    • Removing and installing.
    • Apply a thin coat of Assembly Paste -G 052 150 A2- to piston beforehand
13. Seal
    • Removing and installing.
14. Thrust Nut

Brake Caliper Piston, Removing and Installing

Special tools and workshop equipment required

• Trim Removal Wedge -3409-

Removing

• Rotate the spindle in the direction of -arrow- with an 8 mm socket.

The pressure nut presses the piston out of the brake caliper.

• Remove the piston with the protective boot from the brake caliper.

• Remove the seal with the Trim Removal Wedge -3409-.

Installing

• The surface of the piston and seal must only be cleaned with mineral spirits and then dried.
• Thinly coat piston and seal with Assembly Paste -G 052 150 A2- before inserting.
• Insert the gasket into the brake caliper.

• Place the protective cap with outer sealing lip on the piston.

• Screw the thrust nut so far onto the spindle until the dimension -a- 15 mm has been achieved.

• Using the Trim Removal Wedge -3409-, insert the inner sealing lip of the protective cap into the groove -arrows- in the brake caliper.
• Push the piston onto the thrust nut, which is only possible in four positions.Carefully press the piston into the brake caliper, moving the piston while doing this.
• Carefully press the piston into the brake caliper, moving the piston while doing this.

• Only press the piston so far into the brake caliper until it contacts the thrust nut.

• Carefully turn the spindle clockwise until the thrust nut is at the stop.

• Make sure that the protective cap is seated against the brake caliper -arrows- all around.

• Press the piston into the brake caliper by hand.

The outer sealing lip thereby slips into the groove on the piston.

Brake Caliper, Pre-Bleeding

• Open the bleeder valve -arrow A- and using a commercially available bleeder bottle, fill with brake fluid until brake fluid flows out of the threaded hole (brake hose connection) -arrow B- without any bubbles. Close the bleeder valve.

Position the brake caliper as shown during the pre-bleed procedure.

Pressure Leak Test

Special tools and workshop equipment required

• Brake Pressure Gauge -VAG1310A-
• Brake Pressure Gauge - Adapter M10 -VAG1310/6-

Test Requirement

Brake system (hydraulic unit, brake hoses, brake lines and brake calipers) operating properly and free of leaks.

• Remove the bleeder valve at one of the front brake calipers. Connect the Brake Pressure Gauge -VAG1310A- and bleed.
• Apply pressure to the brake pedal until the pressure gauge indicates a pressure of 50 bar (725 psi). The pressure must not drop more than 4 bar (58 psi) during the test period of 45 seconds. Replace the brake master cylinder if the pressure decrease is too high.