Embedded Files
IMPORTANT!
Install requires removing the caliper carrier. The bolts for these carriers can be reused once. Thoroughly clean the threads, or replace during install for safety.
When removing the brake calipers, hang them from the coil or fender. DO NOT LET IT HANG FROM THE BRAKE LINE.
This kit includes rotor plates, hose flanges and hoses only. We do not include an inlet for the ducts. You will need to source and route those parts yourself.
Some common inlet locations are into the front bumper, lower control arm, or into a splitter if you run one.
TABLE OF CONTENTS
Brake Shield Install
Jack up the front of the car.
NEVER WORK UNDER A CAR THAT IS ONLY SUPPORTED BY A FLOOR JACK.
At a minimum, use cribbing under the subframe, preferably use jack stands. Remove the front tires.
2. Remove the caliper carrier bolts with a 21 mm socket.
3. Hang the caliper from the coil or fender with a hook or similar. Ensure that the brake line is not strained!
4. Remove the rotor retainer bolt with a T30 torx. Remove the rotor. Carefully set it aside so you don't dent the rotor surface.
5. Remove the three bolts that retain the OEM Brake shield with a T30 torx.
6. Install the CJM brake shield reusing the OEM hardware. Hang the rotor back on the hub, temporarily install the T30 retaining screw.
7. Measure the distance between the back surface of the rotor and the shield.
If the distance is larger than 5mm (3/16"), add washers between the shield and spindle to move the shield closer to the rotor. The shield should be as close too the rotor as possible without touching. 5mm (3/16") is the goal.
We include a set of thin and thick washers, as well as extended bolts to acheive the best fit with a variety of rotors. Use the OEM bolts if you are using no washers. Use the included hardware if washers are needed for your rotors.
Once you find the best fit for your car, install the shield bolts and torque to 12Nm / 8.8 ft-lb.
8. On the passenger side, some ABS sensors will rub the hose flange if you are not using any washers between the spindle and shield. This corner of the clip can be shaved down with a knife without compromising the clip engagement.
9. Reinstall the rotor, and retaining bolt with a T30. Torque to 3 ft-lb / 4 N m
Reinstall the caliper & carrier bracket with NEW OEM bolts, or thoroughly clean the original bolts and apply anti-sieze. Torque to 200 Nm / 148 ft-lb. These bolts can be safely re-torque once per VW spec.
Hose Routing
1. The hose has a oval-ed section at the center. The semi-major axis of the oval (wider length) should be parallel to the ground. The round ends of the hose are the same length, so in/out orientation does not matter.
Attach the hose to the inlet with a clamp.
2. Fish the hose between the sway bar, and engine bay. It should be below the axle shaft
3. Tuck the hose into the cavity between the subframe bolt, and sway bar.
4. Run the hose outward, along the steering linkage to the duct.
5. Attach it onto the back of the brake shield flange with a clamp.
6. Turn the steering wheel all the way to the right. In this orientation, now install zip ties on the driver side of the car. Install the short zip tie at the tie rod end, around the hex shank so that it stays in place. check to ensure that it is not pulling on the brake shield.
7. Add the long zip tie around the subframe sheet metal (yellow line).
8. Turn the steering wheel lock to lock a few times and check that the brake hose and ABS line are moving freely and wont rub the axle shaft or wheel. They should be in front of the duct hose.
8. Turn the wheel all the way to the left, and repeat for the passenger side.
Double check the brake and ABS lines are in front of the duct hose.
Google Sites
Report abuse