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Hydraulic Components: Overview Volkswagen Golf Mk7

Mechanical - Hydraulic 6 illustrations ~1457 words

FRONT BRAKE CALIPER ASSEMBLY OVERVIEW, FN3

Note. Install complete repair kit when servicing. Only use mineral spirits to clean brake parts. Apply thin coat of assembly paste G 052 150 A2 to brake cylinders, pistons and seals.

Scheme 1

Scheme 1: FRONT BRAKE CALIPER ASSEMBLY OVERVIEW, FN3
Scheme 1: FRONT BRAKE CALIPER ASSEMBLY OVERVIEW, FN3
  1. Dust Cap Install onto bleeder valve.
  2. Bleeder Valve 10 Nm Apply a thin coat of assembly paste G 052 150 A2 to the threads before screwing in.
  3. Caps Insert in bushing.
  4. Guide Pins 30 Nm
  5. Bushing Insert in brake caliper.
  6. Brake Caliper
  7. Brake Carrier Bolt to brake caliper.
  8. Retaining Spring Insert with both ends in holes of brake caliper.
  9. Seal Removing and Installing, refer to «FRONT BRAKE CALIPER PISTON»(ref-480954-S23977618572012061900000) .
  10. Pistons Removing and Installing, refer to «FRONT BRAKE CALIPER PISTON»(ref-480954-S23977618572012061900000) . Apply thin coat of assembly paste G 052 150 A2 to piston before inserting.
  11. Protective Cap Removing and Installing, refer to «FRONT BRAKE CALIPER PISTON»(ref-480954-S23977618572012061900000) . Do not damage when installing piston.

Scheme 2

Scheme 2: FRONT BRAKE CALIPER OVERVIEW, FNR-G
Scheme 2: FRONT BRAKE CALIPER OVERVIEW, FNR-G

Note. Install complete repair kit when servicing. Only use mineral spirits to clean brake parts. Apply thin coat of assembly paste G 052 150 A2 to brake cylinders, pistons and seals.

  1. Cap Installed on the bleed valve.
  2. Bleed Valve 12 Nm Apply a thin coat of lithium grease G 052 150 A2- to the threads before installing.
  3. Cap Inserted in the bushings.
  4. Guide Pins 30 Nm
  5. Bushing Inserted in the brake caliper.
  6. Brake Caliper Must not be separated.
  7. Brake Carrier Bolted to the brake caliper.
  8. Seal Removing and installing, refer to 1/2 «FRONT BRAKE CALIPER PISTON, FNR-G»(ref-480954-S32936745542012061900000) .
  9. Piston Removing and installing, refer to 1/2 «FRONT BRAKE CALIPER PISTON, FNR-G»(ref-480954-S32936745542012061900000) . Apply thin coat of lithium grease G 052 150 A2- to the piston before installing.
  10. Cap Removing and installing, refer to «FRONT BRAKE CALIPER PISTON, FNR-G»(ref-480954-S32936745542012061900000) . Do not damage when installing the piston.
  11. Spring Insert in the brake pad retaining spring and press below the brake carrier.

REAR BRAKE CALIPER ASSEMBLY OVERVIEW, C 38

Note. Install complete repair kit when servicing. Only use mineral spirits to clean brake parts. New brake calipers are filled with brake fluid and are pre-bled. Apply thin coat of assembly paste G 052 150 A2 to brake cylinders, pistons and seals. In case of repair, brake calipers must always be pre-bled before being installed into vehicle (without brake pads). Refer to REAR BRAKE CALIPER, PRE-BLEEDING .

Scheme 3

Scheme 3: REAR BRAKE CALIPER ASSEMBLY OVERVIEW, C 38
Scheme 3: REAR BRAKE CALIPER ASSEMBLY OVERVIEW, C 38
  1. Brake Caliper with Parking Brake Cable Lever Replace brake caliper if leaking at parking brake cable lever. Pre-bleed brake caliper after repairing. Refer to «REAR BRAKE CALIPER, PRE-BLEEDING»(ref-480954-S36903788082012061900000) .
  2. Dust Cap
  3. Bleeder Valve 10 Nm Apply a thin coat of assembly paste G 052 150 A2 to the threads before screwing in.
  4. Bolt Self-locking 35 Nm Replace. When loosening and tightening, counter-hold at guide pin.
  5. Guide Pins Lubricate before installing the cap.
  6. Cap Install on brake carrier and guide pin.
  7. Brake Carrier with Guide Pins and Protective Caps 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.
  8. Cap Pull onto piston with outer sealing lip. Removing and Installing, refer to «REAR BRAKE CALIPER PISTON, C 38 & CII 41»(ref-480954-S09405981832012061900000) .
  9. Piston with Automatic Adjustment Removing and Installing, refer to «REAR BRAKE CALIPER PISTON, C 38 & CII 41»(ref-480954-S09405981832012061900000) . Apply thin coat of assembly paste G 052 150 A2 to piston before inserting.
  10. Seal Removing and Installing, refer to «REAR BRAKE CALIPER PISTON, C 38 & CII 41»(ref-480954-S09405981832012061900000) .

REAR BRAKE CALIPER ASSEMBLY OVERVIEW, BOSCH

Note. Install complete repair kit when servicing. Only use mineral spirits to clean brake parts. New brake calipers are filled with brake fluid and are pre-bled. Apply thin coat of assembly paste G 052 150 A2 to brake cylinders, pistons and seals. In case of repair, brake calipers must always be pre-bled before being installed into vehicle (without brake pads). Refer to REAR BRAKE CALIPER, PRE-BLEEDING .

Scheme 4

Scheme 4: REAR BRAKE CALIPER ASSEMBLY OVERVIEW, BOSCH
Scheme 4: REAR BRAKE CALIPER ASSEMBLY OVERVIEW, BOSCH
  1. Brake Caliper with Parking Brake Cable Lever Replace brake caliper if leaking at parking brake cable lever. Bleed the brake caliper after servicing, refer to «REAR BRAKE CALIPER, PRE-BLEEDING»(ref-480954-S36903788082012061900000) .
  2. Bleeder Valve 10 Nm Apply a thin coat of assembly paste G 052 150 A2 to the threads before installing.
  3. Dust Cap
  4. Bolt 35 Nm Self-locking. Replace. When loosening and tightening, counter-hold at guide pin.
  5. Upper Guide Pins Lubricate before installing the cap.
  6. Cap Install on brake carrier and guide pin.
  7. Lower Guide Pins With recess. Lubricate before installing the cap.
  8. Guide Grommet On the lower guide pin.
  9. Brake Carrier Supplied as an assembled replacement part with sufficient grease on guide pins. If protective caps or guide pins are damaged use repair kit. Use supplied grease packet to lubricate guide pins.
  10. Cap Pull onto piston with outer sealing lip. Removing and Installing, refer to «REAR BRAKE CALIPER PISTON, BOSCH»(ref-480954-S29358004782012061900000) .
  11. Piston with Automatic Adjustment Removing and Installing, refer to «REAR BRAKE CALIPER PISTON, BOSCH»(ref-480954-S29358004782012061900000) . Apply thin coat of assembly paste G 052 150 A2 to the piston.
  12. Seal Removing and Installing, refer to «REAR BRAKE CALIPER PISTON, BOSCH»(ref-480954-S29358004782012061900000) .

Scheme 5

Scheme 5: REAR BRAKE CALIPER OVERVIEW, CII 41
Scheme 5: REAR BRAKE CALIPER OVERVIEW, CII 41

Note. Install complete repair kit when servicing. Only use mineral spirits to clean brake parts. New brake calipers are filled with brake fluid and are pre-bled. Apply thin coat of assembly paste G 052 150 A2 to brake cylinders, pistons and seals. In case of repair, brake calipers must always be pre-bled before being installed into vehicle (without brake pads). Refer to REAR BRAKE CALIPER, PRE-BLEEDING .

  1. Brake Caliper with Parking Brake Cable Lever Replace the brake caliper if leaking at the parking brake cable lever. Pre-bleed the brake caliper after repairing. Refer to «REAR BRAKE CALIPER, PRE-BLEEDING»(ref-480954-S36903788082012061900000) .
  2. Cap
  3. Bleed Valve 10 Nm Apply a thin coat of assembly paste G 052 150 A2 to the threads before installing.
  4. Bolt 35 Nm Always replace if removed. When loosening and tightening, counter hold at the guide pin.
  5. Guide Pins Lubricate before installing the cap.
  6. Cap Install on the brake carrier and guide pin.
  7. Rear Brake Carrier Supplied as an assembled replacement part with sufficient grease on the guide pins. If the protective cap or guide pins are damaged use them from the repair kit. Use the grease packet supplied to lubricate the guide pins.
  8. Cap Pull onto the piston with outer seal. Removing and installing, refer to 1/2 «REAR BRAKE CALIPER PISTON, C 38 & CII 41»(ref-480954-S09405981832012061900000) .
  9. Piston with Automatic Adjustment Removing and installing, refer to «REAR BRAKE CALIPER PISTON, C 38 & CII 41»(ref-480954-S09405981832012061900000) . Apply thin coat of lithium grease G 052 150 A2 to the piston before installing.
  10. Seal Removing and Installing, refer to «REAR BRAKE CALIPER PISTON, C 38 & CII 41»(ref-480954-S09405981832012061900000) .

BRAKE BOOSTER AND MASTER BRAKE CYLINDER ASSEMBLY OVERVIEW

Note. Use only new brake fluid. Observe information on brake fluid reservoir!

Scheme 6

Scheme 6: BRAKE BOOSTER AND MASTER BRAKE CYLINDER ASSEMBLY OVERVIEW
Scheme 6: BRAKE BOOSTER AND MASTER BRAKE CYLINDER ASSEMBLY OVERVIEW
  1. Pedal Assembly
  2. Nut Self-locking 25 Nm Always replace if removed.
  3. Gasket For brake booster.
  4. Brake Booster On gasoline engines, the required vacuum is supplied either by the intake manifold or by a mechanical vacuum pump. Some gasoline vehicles with a DSG transmission, but not having an hydraulic brake booster, have an electric brake vacuum pump -V192-, refer to «BRAKE SYSTEM VACUUM PUMP»(ref-480954-S38817890912012061900000) . On Diesel engines, a vacuum pump is installed for vacuum creation. Refer to «BRAKE BOOSTER VACUUM PUMP, DIESEL»(ref-480954-S31356634272012061900000) . Functional check: -- With engine switched off, depress brake pedal firmly several times (to exhaust the vacuum in the unit). -- Depress and hold brake pedal with average foot pressure and start engine. If brake booster is working properly, pedal will be felt to give noticeably under foot (booster assistance becomes effective). Replace completely if there are malfunctions (check the vacuum system for the brake booster first; refer to «BRAKE BOOSTER VACUUM SYSTEM, CHECKING»(ref-480954-S10672348972012061900000) . Removing and Installing, refer to «BRAKE BOOSTER»(ref-480954-S16083065992012061900000) .
  5. Seal
  6. Brake Master Cylinder Cannot be serviced. Replace as complete unit if malfunctioning. Removing and Installing, refer to «BRAKE MASTER CYLINDER»(ref-480954-S27583911402012061900000) .
  7. Brake Light Switch -F- Includes brake pedal switch -F47-. Removing and Installing, refer to «BRAKE LAMP SWITCH»(ref-480954-S00706894302012061900000) .
  8. Bolt 5 Nm
  9. Clip
  10. Heat Shield
  11. Nut Self-locking 25 Nm Always replace if removed.
  12. Brake Line 14 Nm Master brake cylinder/secondary piston circuit to hydraulic unit.
  13. Brake Line Master brake cylinder/primary piston circuit to hydraulic control unit.
  14. Sealing Plugs Moisten with brake fluid and press into brake fluid reservoir.
  15. Brake Fluid Reservoir
  16. Cap
  17. Vacuum Hose Insert into brake booster.
  18. Vacuum Diaphragm -G608- On vehicles with a hydraulic brake booster. Removing and Installing, refer to «VACUUM SENSOR»(ref-480954-S35651240122012061900000) . NOTE: Some vehicles without a hydraulic brake booster have a brake booster pressure sensor -G294-. Brake booster pressure sensor, removing and installing, refer to «BRAKE BOOSTER PRESSURE SENSOR»(ref-480954-S21655601802012061900000) .
  19. Sealing Plugs Connection for vacuum hose.

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