Volkswagen Corrado (1993 year). Manual - part 109

 

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Volkswagen Corrado (1993 year). Manual - part 109

 

 

BRAKE SYSTEM 

         1) Raise and support vehicle. Disengage parking brake. Loosen
locking nuts at parking brake lever. Tighten adjusting nuts until
levers on calipers just move off stops. Measure gap between stop and
lever. See Fig. 3.
         2) Maximum clearance between parking brake lever (on caliper)
and stop is .060" (1.5 mm). Apply and release parking brake. Ensure
rear wheels rotate freely. Tighten lock nuts.

Fig. 3:  Adjusting Rear Disc Parking Brake
Courtesy of Volkswagen United States, Inc.

         WHEEL BEARINGS

NOTE:    Front wheel bearings, also called hub or axle bearings, are
         sealed units with 1-piece outer race. Bearings are not
         adjustable.

         Rear Wheel Bearings
         Tighten adjusting nut snugly while turning drum or rotor.
Back off and retighten nut just until axial movement is eliminated.
Install locking cap and NEW cotter key. Install dust cap.

         REMOVAL & INSTALLATION

         FRONT DISC BRAKE PADS

BRAKE SYSTEM 

Fig. 5:  Identifying Front Disc Brake Components
Courtesy of Volkswagen United States, Inc.

         Removal
         1) Raise and support vehicle. Remove front wheels. Hold lower

BRAKE SYSTEM 

         Installation
         1) Seat caliper piston fully into cylinder bore. Install
inner pad and then outer pad. Swing caliper assembly down. Hold lower
guide pin using an open end wrench.
         2) Install lower caliper mounting bolt. Depress brake pedal
several times to allow pads to move into operating position. Ensure
master cylinder reservoir fluid level is full.

         FRONT & REAR BRAKE CALIPER

         Removal & Installation
         1) Raise and support vehicle. Remove wheels. Disconnect
brakeline from caliper, and plug openings. Bend back locking tabs (if
equipped) on mounting bolts. If removing rear brake calipers,
disconnect parking brake cables.
         2) On all calipers, remove caliper mounting bolts. See Fig. 4
or 6. Remove caliper assembly from wheel bearing housing. To install,
reverse removal procedure. Use NEW lock plates (if equipped) and
mounting bolts. Bleed hydraulic brake system. See BLEEDING PROCEDURES
under BLEEDING BRAKE SYSTEM.

         FRONT & REAR BRAKE ROTOR

         Removal
         Raise and support vehicle. Remove wheels. Remove caliper and
suspend from frame with wire. Remove countersunk screw that holds
rotor to hub. Pull rotor off hub.

         Installation
         To install, reverse removal procedure. Adjust wheel bearings
(if necessary). See WHEEL BEARINGS under ADJUSTMENTS.

         REAR DISC BRAKE PADS

         Removal
         Raise and support vehicle. Remove rear wheels. Disconnect
parking brake cable from caliper. Remove caliper mounting bolts.
Remove caliper and wire aside. Siphon small amount of brake fluid from
reservoir. Remove pads and retaining springs from caliper support.
Replace pads that exceed wear limit. Wear limit of pads is .28" (7.0
mm), including backing plate.

         Installation
         Seat caliper piston fully into cylinder bore. Install inner
pad first and then install outer pad. Position caliper. Install

BRAKE SYSTEM 

         MASTER CYLINDER

         Removal
         1) Drain master cylinder reservoir. Remove cover plate (if
equipped). Disconnect brakelines and wiring at master cylinder.
         2) On models without power assist servo, disconnect brake
push rod at brake pedal. On models equipped with power assist servo,
remove master cylinder from servo. Be careful to keep any spacers used
on attaching bolts for proper installation.

         Installation
         To install, reverse removal procedure. Always use NEW "O"
ring between master cylinder and power assist servo. Bleed hydraulic
system.

         VACUUM POWER ASSIST SERVO

         Removal
         Remove master cylinder from power assist servo. Disconnect
brake push rod from brake pedal. Disconnect vacuum hose from servo.
Remove servo from vehicle.

NOTE:     Not all vehicles have all components.

         Installation
         To install, reverse removal procedure. Before attaching brake
push rod to brake pedal, check and adjust push rod length. Always use
NEW damping ring, washer, filter and "O" ring (as equipped). Slots in
damping washer and filter must be offset 180 degrees (if equipped).
Complete installation, and bleed hydraulic system.

         OVERHAUL

NOTE:    Black staining from piston seal wear may show on caliper
         bore walls and piston. This staining is normal. DO NOT
         disassemble power assist servo as parts are not available.

         Refer to appropriate illustration for caliper and master
cylinder overhaul. See Figs. 6 and 7.

 

 

 

 

 

 

 

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