Installation instructions for the Epytec brake system kit with the 6-piston Porsche Panamera brake callipers on the VW Golf 7 8 Audi A3

Installation instruction for article no. 511-Kit, here you will learn how to proceed step by step.

Scope of delivery article no.511 Kit

2x Cayenne 958 GTS Panamera brake calipers part number: 7PP615149J / 7PP615150J ( left / right ) including complete new brake caliper bracket kit
matching set EBC Sport brake discs Turbo Groove MERCEDES-BENZ ML/ GL-KLASSE 375x36mm
2x ceramic brake pads for less brake dust and longer service life
2x brake caliper adapter for VW Golf 7 8 Audi A3 Cupra Leon Seat Leon Skoda and many more
2x matching steel flex lines
2x centring ring high-strength screw material

Please note

Please read these instructions carefully before starting work. If the conversion is too difficult for you, please commission a specialist garage to carry out the installation. We cannot accept any liability for consequential damage caused by improper installation. Correct installation and adjustment saves time, costs and trouble

Disassembly:

Old brake system (brake disc, brake caliper and brake caliper carrier)
Remove or process the air baffle or brake baffle or anchor plate (we prefer removal, as the ventilation of the brake is better ensured). !!!Important!!

!!Important!!

It is essential to check that there are no rust or paint residues on the bolt-on points of the steering knuckle or wheel hub. If this is the case, please clean them. Then check the threads of the steering knuckle for damage.

What do you need to do that?

Depending on your technical knowledge, about 1-2 hours of time
Torque spanner with suitable attachments
Liquid threadlocker

Dismantle the old brake system:

Jack up the car or use a lifting platform
To remove the old brake system, the car must be jacked up or, in the best case, you have a lifting platform available.

Remove the rim

The first step is to remove the rim

To do this, you need a wheel spider or spanner. To do this, loosen all the wheel nuts and then remove the wheel and rim.

Remove the original brake system

When the rim has been removed and the brake system is free, it can be loosened. To do this, remove the bolts behind the axle.

Use a screwdriver to loosen the brake line at the retaining clip.

When everything has been loosened, simply leave the brake calliper on the old brake line so that the brake fluid does not leak out.

Then you can simply pull the brake calliper off the brake disc.

If the brake calliper is a little tighter, simply use a large flat-blade screwdriver to push it between the brake calliper and the brake disc and then push the brake calliper away from the brake disc with a minimum of force.

Remove the old brake disc and the heat shield

As soon as the brake disc is freely accessible, you can loosen the fastening screws and remove the brake disc from the wheel hub

Now you can remove the heat shield by removing the 3 fastening screws (see red markings). Then you can simply pull it down over the wheel hub.

If the screws are stuck, it is recommended to spray the screws with rose solvent so that they can be loosened more easily.

Remove dirt and rust from the wheel hub and the mounting points on the axle

Now you should clean the wheel hub and the mounting points of the adapter on the axle with an angle grinder with a wire brush attachment, for example, so that you have a clean and flat contact surface and an optimal fit for the adapter is given.

If you don't have an angle grinder, you can also use a conventional wire brush.

Adjust wear indicator, if available

(If you don't have a wear indicator sensor, you can skip this point)

To do this, lever out the wear indicator sensor on the original brake caliper and from the brake pad holder using a slotted screwdriver.

Next, remove the wear indicator connector. The best way to do this is to use a slotted screwdriver, which you can use to carefully pry open the connector.

Bend the wear indicator bracket up and to the side

In order for you to be able to mount the Epytec tuning adapter, the holder for the wear indicator must be bent upwards. Depending on the model, this may only be on one side of the axle or your vehicle may not have a wear indicator at all.

The best thing to do is to use a pipe wrench and carefully bend the holder upwards and to the side so that there is enough space

Example, this is what it should look like in the end

Make sure there is at least 8mm space for the brake caliper and Epytec tuning adapter.

Reconnecting the wear indicator on the car

Once the wear indicator bracket is bent up and to the side, the cable can be re-inserted into the cable guide bracket.

First tie the wear indicator together so that it takes up little space.

The easiest way to do this is to turn the wear indicator by 180° and pull a heat shrink tube over it.

This way the wear indicator remains protected and original and can be reused if necessary, should you retrofit the brake system.

Afterwards you can clamp the indicator back into the curved holder on the vehicle.

This way you still have everything, should you ever need to retrofit it again.

Installation of the new brake system

Fitting the Epytec Tuning Adapter

Important! Do not forget to use threadlocker! When mounting all high-strength bolts, it is important to use threadlocker.

We recommend using medium-strength threadlocker on the first three to five threads.

Now you can put the centring ring for the brake disc on the wheel hub so that the brake disc is optimally centred on the wheel hub and you have no slack.

Now the tuning adapter is screwed to the axle mount with the supplied high-strength M14x55mm screws.

The engraving must point in the direction of the engine compartment, then you know that the tuning adapter is correctly mounted.

This also has the advantage that the engraving can be easily read by the TÜV inspector from the inside (underneath the vehicle) and is not covered by the brake disc.

Fitting the brake disc

As soon as the Epytec Tuning Adapters are mounted, you can mount the brake disc on the wheel hub.

In our case we directly used a mounting aid, which makes the whole assembly much easier.

The included assembly aid is used here, which makes the entire assembly process much easier. The assembly aid is required, otherwise the brake disc will not hold until the 6-piston Porsche Panamera brake caliper is installed.

Greasing the brake pads / brake calliper with brake paste

Before fitting the Porsche Panamera brake callipers, the brake pads and the brake callipers must be greased with brake paste (see pictures blue arrows).

!! Important!!

Do not apply grease to the direct brake pads, only to the top of the guide (blue arrow) brake pads. Likewise, no grease may get on the brake disc or piston, but only on the guide pins of the brake calliper (blue arrow).

This has the following advantages:

Reduces squeaking noises
Prevents corrosion
Improved braking performance (brake pads have less friction and slide more evenly on the caliper)
Because corrosion is prevented, changing the brake pads is much easier and quicker.

Fitting the pads and retaining clips in the brake calliper

After the brake callipers and brake pads have been greased, the brake pads can be fitted in the brake calliper and secured with the retaining clips.

!!Important!!

Make sure that the pistons are fully retracted so that the brake caliper can be neatly mounted on the brake disc.

If the pistons still protrude a little, they can easily be pushed inwards by hand, as the brake calipers are still empty and not yet connected to the hydraulics :).

Once you have checked the pistons, you can easily insert the retaining clips.

Once the retaining clips are in place, you can simply attach the brake pads using the guide pins and retaining clips.

Fitting the brake calliper to the Epytec Tuning Adapter

Now the Porsche Panamera brake caliper can be mounted carefully on the brake disc and the Epytec Tuning Adapter. To do this, carefully guide the brake caliper over the brake disc and fix it to the Epytec Tuning Adapter using the high-strength M14x100mm screws supplied.

!!Important!!

Do not forget to use threadlocker!

!! Important!!

the bleed nipple of the brake system must point upwards during assembly.

Checking the brake disc for free movement and steering angle

As soon as the brake caliper has been mounted on the new brake disc, you can check the brake disc for free movement and steering angle and whether anything is rubbing against it when the steering wheel is fully turned. To do this, it is best to turn it completely to the left and right to check whether anything is in the way, e.g. suspension joint, wishbone, etc.

Dismantle the old brake line and brake calliper.

Now you can completely remove the old brake caliper and the old brake line. To remove the brake line, first carefully loosen the retaining clip on the vehicle side and remove it from the guide bracket behind the brake disc. Then the brake line can be removed from the old brake calliper and the brake calliper can be finally dismantled.

Fitting the new steel braided line

Once the old brake lines have been removed, you can fit the new steel braided line.

First press the new steel braided line into the holder on the vehicle side and then fasten it again with the clip.

Then clamp back into the guide holder

and attach it to the Porsche Panamera brake calliper.

For easier attachment, we have manufactured the steel braided line with a curved connection, which prevents the line from kinking.

Bleeding the brake system

Once the steel braided lines and the brake system have been refitted, the brake system must be bled. This means that all the air must be removed from the brake system and the brake calipers filled with brake fluid.

It is best to do this in pairs and proceed as follows:

Check brake fluid

Make sure that there is enough brake fluid in the reservoir.

Bleeding

Open the sealing cap

Put a hose (preferably transparent, then you can see it better) on the bleed valve and immerse the end in a collection container with brake fluid.

Then open the bleed valve slightly, now slowly press the brake pedal down to the floor and hold it there.

Close the bleed valve again, the brake pedal can now be released.

This procedure must be repeated until no more air bubbles can be seen in the hose and the brake fluid runs evenly.

Cleaning the brake disc and caliper

After bleeding, it is important that the brake disc and calipers are cleaned of the remains of the brake fluid, as the brake fluid is corrosive and could etch the calipers and brake discs.

Check the clearance of the rim and brake calliper.

After the complete brake system has been cleaned, you can mount the rim

We recommend that you use our rim mounting aids. It is best to use 2 rim mounting aids so that the 5 holes of the rim are centred optimally.

!!Important!!

Please check whether you have enough space between the wheel spider and the brake system. If this is not the case, a wheel spacer must be installed to ensure clearance.

A clearance of at least 3mm from the rim spider to the brake calliper must be ensured, otherwise a wheel spacer must be installed.