SYS.OK|MANUAL.DB● LIVE
HOMESERVICE MANUALSVOLKSWAGEN2002GOLF GLS, 2.0 K, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 155 (MECHANICAL COMPONENTS - BRAKE SYSTEM (SEDAN) (A5 PLATFORM))46 MECHANICAL COMPONENTSDESCRIPTION AND OPERATIONFN 3 FRONT CALIPER ASSEMBLY OVERVIEW
2002 Volkswagen Golf GLS, 2.0 K, Standard

FN 3 Front Caliper Assembly Overview

2002 Volkswagen Golf GLS, 2.0 K, StandardSECTION FN 3 Front Caliper Assembly Overview
WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2010 Volkswagen Jetta, 2009 Volkswagen Jetta, 2009 Volkswagen GLI, 2008 Volkswagen Jetta, and 2008 Volkswagen GLI. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:

After replacing brake pads, depress brake pedal several times firmly to properly seat brake pads in their normal operating position.

Use Brake Charger/Bleeder Unit VAS 5234 or Extraction Device Upgrade Kit V.A.G 1869/4 to extract brake fluid from brake fluid reservoir.

Before removing brake caliper or disconnecting brake hose, Brake Pedal Depressor V.A.G 1869/2 must be inserted (this dissipates pressure).

Assembly Overview FN3 15 Inch

Fig 1: Exploded View Of Front Brake Components
GWWM46-0130Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
  1. Bolt, 4 Nm
  2. Brake Disc
    • Internally vented, ø 288 mm
    • Thickness 25 mm
    • Wear limit: 22 mm
    • Must always be replaced together on both sides of vehicle.
    • Remove brake caliper 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.
    • Check thickness
    • Must always be replaced together on both sides of vehicle
    • Removal and installation, refer to BRAKE PADS .
  4. Retaining Spring
    • Insert in both holes of brake caliper.
  5. Brake Carrier
    • Bolt to wheel bearing housing.
  6. Brake Caliper
  7. Guide Pins, 30 Nm
  8. Cap
    • Remove
  9. Brake Hose with Ring Connection and Banjo Fitting, 35 Nm
  10. Ribbed Bolt, 190 Nm
    • Clean if using again.
  11. Bolt
  12. Bracket
  13. Wheel Bearing Housing
    • With bolted 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. Bolt, 8 Nm
  16. Cover Plate
  17. 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 Wheel Hub Unit
    • The ABS sensor ring is installed in the wheel bearing.

Assembly Overview FN3 16 Inch

Fig 2: Exploded View Of Front Brakes, FN 3 Calipers -- Assembly Overview FN3 16 Inch
GWWN46-10091Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
  1. Bolt, 12 Nm
  2. Brake Disc
    • Internally vented, ø 312 mm
    • Thickness 25 mm
    • Wear limit: 22 mm
    • Must always be replaced together on both sides of vehicle.
    • Remove brake caliper and brake carrier before removing.
  3. 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.
    • Check thickness
    • Must always be replaced together on both sides of vehicle.
    • Removal and installation, refer to BRAKE PADS .
  5. Retaining Spring
    • Insert in both holes of brake caliper.
  6. Brake Carrier
    • Bolt to wheel bearing housing.
  7. Brake Caliper
  8. Guide Pins, 30 Nm
  9. Cap
    • Remove
  10. Brake Hose with Ring Connection and Banjo Fitting, 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 bolted 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. Bolt, 8 Nm
  19. Wheel Bearing and Wheel Hub Unit
    • The ABS sensor ring is installed in the wheel bearing.
  20. Cover Plate
RENDER: 1.0x

NO RELATED

Recommended Tools & Savings

Use the Manual With the Right Hardware

Pair factory procedures with proven DIY tools so the instructions are easier to execute.

Affiliate disclosure: We may earn a commission at no extra cost to you.

Shop Manual-Ready ToolsFree Quote CheckQuote Shield Pro

When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.