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Mechanical Components: Overview Volkswagen Eos I

Mechanical - Hydraulic 5 illustrations ~1302 words

FRONT BRAKES, FS III CALIPER OVERVIEW

Note. After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the brake pads are properly seated in their normal operating position. Use brake charger/bleeder unit VAS 5234 or extraction device V.A.G 1869/4 to extract brake fluid from brake fluid reservoir. Before removing brake caliper or disconnecting brake hose, brake pedal actuator V.A.G 1869/2 must be inserted (this dissipates pressure).

Scheme 54

Scheme 54: FRONT BRAKES, FS III CALIPER OVERVIEW
Scheme 54: FRONT BRAKES, FS III CALIPER OVERVIEW
  1. Hex Head/Torx® Bolt 12 Nm Hex head bolt M6x10 changed from Torx® bolt M6x12 Replace hex head bolt with hex head bolt and Torx® bolt with Torx® bolt
  2. Brake Rotor Internally vented, 280 mm diameter Thickness: 22 mm Wear limit: 19 mm Must always be replaced together on both sides of axle Remove brake caliper before removing
  3. Phillips Head- / Torx® Bolt 4 Nm
  4. Brake Pads Thickness: 14 mm without backing plate With wear indicator When wear limit is reached (limit: approximately 4 mm), the warning lamp lights up in instrument cluster Wear limit: 2 mm without backing plate Checking thickness «MAINTENANCE PROCEDURES»(ref-475587-S15524971022012052300000) Must always be replaced together on both sides of axle Removing and installing, refer to
  5. Harness Connector Brake pad wear indicator
  6. Brake Caliper Do not remove brake hose when replacing brake pad Removing and installing, refer to
  7. Guide Pins 30 Nm
  8. Cap Remove
  9. Brake Hose with Banjo Fitting and Union Bolt 35 Nm
  10. Guide Pins 30 Nm
  11. Cap Remove
  12. Bolt
  13. Bracket
  14. Wheel Bearing Housing With integrated brake carrier
  15. ABS Wheel Speed Sensor Before inserting sensor, clean inner surface of bore hole and coat with hot bolt paste G 052 112 A3
  16. Hex Socket Head Bolt 8 Nm
  17. Wheel Bearing/Hub Unit The ABS sensor ring is installed in the wheel bearing
  18. Cover Plate

FRONT BRAKES, FN 3 CALIPER OVERVIEW

Note. After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the brake pads are properly seated in their normal operating position. Use brake charger/bleeder unit VAS 5234 or extraction device V.A.G 1869/4 to extract brake fluid from brake fluid reservoir. Before removing brake caliper or disconnecting brake hose, brake pedal actuator V.A.G 1869/2 must be inserted (this dissipates pressure).

Assembly Overview FN3 15 Inch

Scheme 55

Scheme 55: FRONT BRAKES, FN 3 CALIPER OVERVIEW
Scheme 55: FRONT BRAKES, FN 3 CALIPER OVERVIEW
  1. Phillips Head / Torx® Bolt 4 Nm
  2. Brake Rotor Internally vented, 288 mm diameter Thickness: 25 mm Wear limit: 22 mm Must always be replaced together on both sides of axle Remove brake caliper and brake carrier before removing
  3. Brake Pads Thickness: 14 mm without backing plate With wear indicator When wear limit is reached (limit: approximately 4 mm), the warning lamp lights up in instrument cluster Wear limit: 2 mm without backing plate Checking thickness, refer to «MAINTENANCE PROCEDURES»(ref-475587-S15524971022012052300000) Must always be replaced together on both sides of axle Removing and installing, refer to «BRAKE PADS»(ref-475622-S38257711792012052300000)
  4. Retaining Spring Insert in both holes of brake caliper
  5. Brake Carrier Bolt to wheel bearing housing
  6. Brake Caliper Do not remove brake hose when replacing brake pad Removing and installing, refer to «BRAKE CALIPER»(ref-475622-S37055765842012052300000) Servicing, refer to «FN 3 BRAKE CALIPER OVERVIEW»(ref-475557-S24128984372012052300000)
  7. Guide Pins 30 Nm
  8. Cap Remove
  9. Brake Hose with Banjo Fitting and Union Bolt 35 Nm
  10. Ribbed Bolt 190 Nm Clean if using again.
  11. Bolt
  12. Bracket
  13. Wheel Bearing Housing With fastened brake carrier
  14. ABS Wheel Speed Sensor Before inserting sensor, clean inner surface of bore hole and coat with hot bolt paste G 052 112 A3
  15. Hex Socket Head Bolt 8 Nm
  16. Cover Plate
  17. Hex Head/Torx® Bolt 12 Nm Hex head bolt M6x10 changed from Torx® bolt M6x12 Replace hex head bolt with hex head bolt and Torx® bolt with Torx® bolt
  18. Wheel Bearing/Hub Unit The ABS sensor ring is installed in the wheel bearing

Assembly Overview FN3 16 Inch

Scheme 56

Scheme 56
Scheme 56
  1. Torx® Bolt 12 Nm
  2. Brake Rotor Internally vented, 312 mm diameter Thickness: 25 mm Wear limit: 22 mm Must always be replaced together on both sides of axle Remove brake caliper and brake carrier before removing
  3. Torx® Bolt 4 Nm
  4. Brake Pads Thickness 14 mm without backing plate With wear indicator When wear limit is reached (limit: approximately 4 mm), the warning lamp lights up in instrument cluster Wear limit: 2 mm without backing plate Checking thickness, refer to «MAINTENANCE PROCEDURES»(ref-475587-S15524971022012052300000) Must always be replaced together on both sides of axle Removing and installing, refer to «BRAKE PADS»(ref-475622-S38257711792012052300000)
  5. Retaining Spring Insert in both holes of brake caliper
  6. Brake Carrier Bolt to wheel bearing housing
  7. Brake Caliper Do not unscrew brake hose when replacing brake pad Removing and installing, refer to «BRAKE CALIPER»(ref-475622-S37055765842012052300000) Servicing, refer to «FN 3 BRAKE CALIPER OVERVIEW»(ref-475557-S24128984372012052300000)
  8. Guide Pins 30 Nm
  9. Cap Remove
  10. Brake Hose with Banjo Fitting and Union Bolt 35 Nm
  11. Guide Pins 30 Nm
  12. Cap Remove
  13. Bolt
  14. Bracket
  15. Ribbed Bolt 190 Nm Clean if using again.
  16. Wheel Bearing Housing With fastened brake carrier
  17. ABS Wheel Speed Sensor Before inserting sensor, clean inner surface of bore hole and coat with hot bolt paste G 052 112 A3
  18. Hex Socket Head Bolt 8 Nm
  19. Wheel Bearing/Hub Unit The ABS sensor ring is installed in the wheel bearing
  20. Cover Plate

CII 38 REAR BRAKES OVERVIEW

Note. After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the brake pads are properly seated in their normal operating position. Use brake charger/bleeder unit VAS 5234 or extraction device V.A.G 1869/4 to extract brake fluid from brake fluid reservoir. Before removing brake caliper or disconnecting brake hose, brake pedal actuator V.A.G 1869/2 must be inserted (this dissipates pressure).

Scheme 57

Scheme 57: CII 38 REAR BRAKES OVERVIEW
Scheme 57: CII 38 REAR BRAKES OVERVIEW
  1. ABS Wheel Speed Sensor Before inserting sensor, clean inner surface of bore hole and coat with hot bolt paste G 052 112 A3
  2. Hex Socket Head Bolt 8 Nm
  3. Multi-Point Socket Head Bolt Always replace after removing it. 90 Nm plus an additional 90° turn
  4. Wheel Bearing Housing
  5. Cover Plate
  6. Torx® Bolt 12 Nm
  7. Wheel Bearing/Hub Unit
  8. Brake Rotor Diameter: 286 mm Thickness: 12 mm Wear limit: 10 mm Always replace pads on both sides of axle if worn. Remove brake caliper before removing
  9. Bolt 4 Nm
  10. Bolt Only on front wheel drive
  11. Brake Pads Thickness: 11 mm without backing plate Wear limit: 2 mm without backing plate Checking thickness, refer to «MAINTENANCE PROCEDURES»(ref-475587-S15524971022012052300000) Must always be replaced together on both sides of axle Removing and installing, refer to «BRAKE PADS»(ref-475622-S38530127032012052300000)
  12. Brake Carrier with Guide Pins and Protective Cap Supplied as an assembled replacement part with sufficient grease on guide pins If protective caps or guide pins are damaged, install repair kit. Use supplied grease packet to lubricate guide pins
  13. Anti-Rattle Spring Always replace when pads are replaced
  14. Brake Caliper Do not remove brake hose when replacing brake pad Removing and installing, refer to «BRAKE CALIPER»(ref-475622-S25129043032012052300000) Servicing, refer to «CI 38, CII 38 CII 41 BRAKE CALIPERS, REAR BRAKE CALIPER OVERVIEW»(ref-475557-S22401208622012052300000) After servicing or replacing, parking brake cable must be adjusted first. Adjusting the parking brake, refer to «PARKING BRAKE, ADJUSTING»(ref-475622-S15911456972012052300000)
  15. Hose Retainer
  16. Brake Line 14 Nm
  17. Hex Bolt, Self-Locking Replace 35 Nm
  18. Parking Brake Cable Adjusting the parking brake, refer to «PARKING BRAKE, ADJUSTING»(ref-475622-S15911456972012052300000)
  19. Spring Clamp
  20. Brake Hose

BRAKE PEDAL OVERVIEW

WARNINGThe path of the brake pedal must not be shortened via extra floor mats.

Before installing, lubricate all mounting points with grease, part no. G 000 602.

Scheme 58

Scheme 58
Scheme 58
  1. Mounting Bracket
  2. Self-Locking Hex Nut 25 Nm
  3. Brake Lamp Switch -F- Includes brake pedal switch -F47- On vehicles from CW 45/05, brake lamp switch -F- is located on brake master cylinder, refer to «BRAKE BOOSTER AND MASTER BRAKE CYLINDER OVERVIEW»(ref-475557-S35706892492012052300000) Clip brake pedal at pressure rod of brake booster before installing brake light switch «BRAKE PEDAL AND BRAKE BOOSTER»(ref-475622-S00511549692012052300000) . Lubricate tappet head with polycarbamide grease G 052 142 A2. Brake light switch, removing and installing, refer to «BRAKE LAMP SWITCH, FROM 10.05.2005»(ref-475557-S21730216572012052300000)
  4. Hex Head bolt
  5. Brake Pedal
  6. Cover
  7. Ball Socket
  8. Wheel Hub Support For ball head of brake servo push rod
  9. Self-Locking Hex Nut 25 Nm
  10. Bushing
  11. Pivot Pin

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