VOLKSWAGEN GOLF IV

since 1997 of release

Repair and car operation



Foltsvagen Golf 4
+ 1. Maintenance instruction
+ 2. Engine
+ 3. Cooling system
+ 4. Fuel system
+ 5. Exhaust system
+ 6. Ventilation and heating system
+ 7. Coupling
+ 8. Transmission
+ 9. Suspension brackets and power shafts
+ 10. Steering
+ 11. Wheels and tires
- 12. Brake system
   12.1. Technical characteristics
   + 12.2. ABS/EBV/EDS/ASR/MSR
   - 12.3. Replacement of forward brake shoes on FS-III support
      12.3.1. Removal
      12.3.2. Installation
   + 12.4. Replacement of brake shoes on FN-3 support
   + 12.5. Replacement of back brake shoes on disk brakes
   + 12.6. Brake disk
   12.7. Adjustment of the hand brake
   + 12.8. Replacement of back brake shoes on drum-type brakes
   12.9. Removal and installation of the back working brake cylinder
   + 12.10. Pumping of hydraulic brake system
   12.11. Brake pipelines and hoses
   12.12. Check of the vacuum amplifier of brakes
   12.13. Removal, installation and adjustment of the switch of a stoplight
   12.14. Removal and installation of cables of the hand brake
   12.15. Main malfunctions of brakes
+ 13. Body
+ 14. Electric equipment and electroschemes




12.3.2. Installation

PERFORMANCE ORDER

Prevention

Do not press a brake pedal at the removed brake shoes.


1. Clear a dust and dirt from a support and a rust from edge of a brake disk. If blocks are suitable for further operation, clear them, using a wire brush and rags.
2. Check a brake disk on existence of cracks, especially round openings under bolts of fastening of a wheel, and also with existence of wear and mechanical damages and if necessary replace it.
3. Measure thickness of a brake disk.
4. Check a condition of a dustproof cap of the piston of a support and if necessary replace it.

Prevention

At intensive wear of brake shoes check ease of moving of the piston of a support. For this purpose insert wooden whetstone between brake shoes in a support and ask the assistant to press a brake pedal. By pressing a brake pedal the piston should move smoothly, compressing brake shoes. Otherwise make support repair in stationary conditions.


5. If new brake shoes are established, using the special adaptation, press the piston into a support.
6. For piston cave-in in a support it is possible to use a wooden core or the hammer handle. Thus watch, that the piston did not warp also surfaces of the piston and a boot were not damaged.
7. At a piston vdviganiye brake liquid is forced out from the brake cylinder in a broad tank therefore constantly watch liquid level in a tank, and if necessary pump out from a tank its small amount.
8. Establish brake shoes in a support.
9. Since May, 1998 the design of brake shoes is changed. The reverse side of an internal brake shoe is painted in white color. The external brake shoe is painted in black color and has a trekhplechy fixing clip.
10. Establish a support on a rotary fist. First of all the lower part of a support (shooter) by grooves on directing a rotary fist is established.
11. Fix a support directing bolts to a rotary fist and tighten them the moment of 28 Nanometers.
12. Establish protective casings of directing bolts.
13. Establish forward wheels, then lower the car and tighten bolts of fastening of wheels the moment of 120 Nanometers.
14. Check level of brake liquid in a popolnitelny tank and, if necessary, finish it to norm.
15. Several times press a brake pedal that brake shoes nestled on a brake disk.

Prevention

Being careful, let's be earned extra to new brake shoes. For this purpose at about 80 km/h several times brake till speed of 40 km/h in easy pressing of a pedal. In intervals let's to brake shoes be cooled a little.

After installation of new brake shoes avoid sharp braking during the first 200 km of run of the car.


Check of control of safety

PERFORMANCE ORDER
1. Check, whether brake hoses are reliably tightened.
2. Check, whether the brake hose in the holder is fixed.
3. Check, whether pumping unions are reliably tightened.
4. Check, whether level of brake liquid is sufficient.
5. Check make at the working engine. During about 10 seconds press a brake pedal with effort of 20-30 kg/m, thus the pedal should not fail.
6. Check tightness of all listed connections.