Rear brake caliper piston, removing and installing

Special tools, testers and auxiliary items required

Fig 1: Identifying Special Tools - Rear Brake Caliper Piston, Removing And Installing

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V.A.G 1331 Torque wrench
V.A.G 1332 Torque wrench
T10145 Piston resetting tool
Trim Removal Wedge 3409

VAS 5051 Vehicle diagnosis, testing and information system

Removing

Raise vehicle.
Remove wheels.

Fig 2: Data Link Connector (DLC)

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With ignition off, connect Vehicle Diagnosis, Testing and Information System VAS 5051 with diagnostic cable VAS 5051/1 to 16-pin vehicle Data Link Connector (DLC) and select parking brake in OBD using "Address word" 53.

NOTE:

Ignition on
Release parking brake
Coding check and reported if necessary.
DTC memory interrogated, errors shown corrected and DTC memory erased.

Fig 3: Locating Control Module Identification With Code Indicated On Display

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Shown on VAS 5051 display:

Select function "04 - Basic setting".

Fig 4: Identifying Diagnostic Operation System VAS 5051A (Prompt For Entering Display Group Appears In Display Zone & Input Keypad Appears In Display Zone)

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Shown on VAS 5051 display:

The request to enter a display group number appears in display field - 1 -.
An entry keypad is shown in display field - 2 -.

Using entry keypad in display field - 2 - , enter "7" for "Display group number 007" and confirm by pressing Q button (brake opens completely).

Fig 5: Removing/Installing Attachment Bolts From Brake Caliper Housing

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Remove attachment bolts from brake caliper housing, to do so counter-hold guide pins.

NOTE:

Actuator or brake system connector must not be disconnected.

Fig 6: Sliding Connector Out Of Bracket

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Slide connector out of bracket
Remove brake caliper sideways
Remove brake pads
Remove guide clamps OBD; "Address word" 53 parking brake.

Fig 7: Locating Control Module Identification With Code Indicated On Display

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Shown on VAS 5051 display:

Select function "04 - Basic setting".

Fig 8: Identifying Diagnostic Operation System VAS 5051A (Prompt For Entering Display Group Appears In Display Zone & Input Keypad Appears In Display Zone)

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Shown on VAS 5051 display:

The request to enter a display group number appears in display field - 1 -.
An entry keypad is shown in display field - 2 -.

Using entry keypad in display field - 2 - , enter "6" for "Display group number 006" and confirm by pressing Q button (Pistons run together). The brake piston runs out for 20 seconds and falls out of the brake caliper.

NOTE:

If the brake piston has not fallen out after 20 seconds, switch ignition off and back on again after 10 seconds. Then press the electromechanical parking brake switch. The brake piston runs out again for another 20 seconds.

Switch ignition off.
Remove brake piston and pressure nut from brake caliper.
Remove old protective cap from brake piston.

Fig 9: Removing Old Seal From Brake Caliper Using Trim Removal Wedge 3409

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Remove old seal from brake caliper using Trim Removal Wedge 3409.

Installing

Install new seal in brake caliper.

Fig 10: Placing New Protective Cap On Brake Pistons

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Place new protective cap on brake pistons as shown.

Fig 11: Installing Pressure Nut In Brake Caliper As Far As Stop

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Install pressure nut - 1 - in brake caliper as far as stop and then loosen pressure nut a quarter turn.

Fig 12: Inserting Protective Cap In Brake Caliper Groove Using Trim Removal Wedge 3409

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Insert protective cap in brake caliper groove. Use Trim Removal Wedge 3409 to do so.
Carefully slide brake piston into brake caliper. Move brake piston when doing so. Brake piston must be guided over pressure nut, this is only possible in four positions.

Fig 13: Pressing It As Far As Stop Into Brake Caliper

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After brake piston has been guided onto pressure nut, press it as far as stop into brake caliper.

NOTE:

Ensure pressure nut is not damaged.

Fig 14: Pressing Pistons Back Using Piston Resetting Tool T10145

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Piston resetting tool T10145 can also be used to press brake piston back in.
Ensure protective cap is guided into brake piston groove when piston is pressed all the way in.

Fig 15: Inserting Pad Retaining Springs

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Insert brake pad retaining springs
Measure pad strength of both brake pads without backing plates and note smaller value.

NOTE:

Round measured value to a whole number. The value must be between 3 and 14. If the value is under 3, use new brake pads.

Fig 16: Identifying Brake Pads, Guide Clips & Brake Caliper Housing

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Insert brake pads.

Fig 17: Identifying Brake Pads Are Located Correctly In Anti-Rattle Springs

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Make sure that the brake pads are located correctly in anti-rattle springs - arrows -.

Fig 18: Removing/Installing Attachment Bolts From Brake Caliper Housing

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Secure brake caliper housing using new self-locking bolts.

NOTE:

The repair kit includes four self-locking hex bolts which must be installed in all cases.

Fig 19: Installing Electronic Parking Brake Connector In Bracket

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Install electronic parking brake connector in bracket.
Switch on ignition.
Close and open electrical parking brake three times. Wait each time until parking brake actuator has reached the end position.
Switch ignition off and back on again after 10 seconds. OBD; "Address word" 52 parking brake.

Fig 20: Locating Control Module Identification With Code Indicated On Display

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Shown on VAS 5051 display:

Select function "04 - Basic setting".

Fig 21: Identifying Diagnostic Operation System VAS 5051A (Prompt For Entering Display Group Appears In Display Zone & Input Keypad Appears In Display Zone)

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Shown on VAS 5051 display:

The request to enter a display group number appears in display field - 1 -.
An entry keypad is shown in display field - 2 -.

Using entry keypad in display field - 2 - , enter "10" for "Display group number 10" and confirm by pressing Q button (system check). Brake function is checked. The electronic parking brake opens and closes completely three times. OBD; "Address word" 52 parking brake.

Fig 22: Locating Control Module Identification With Code Indicated On Display

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Shown on VAS 5051 display:

Selection function "10 - Adaptation".

Fig 23: Identifying Diagnostic Operation System VAS 5051A (Prompt For Entering Display Group Appears In Display Zone & Input Keypad Appears In Display Zone)

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Shown on VAS 5051 display:

The request to enter a channel number appears in display field - 1 -.
An entry keypad is shown in display field - 2 -.

Using entry keypad in display field - 2 - , enter "6" for "Display group number 06" and confirm by pressing Q button (pad thickness entry).

Fig 24: Identifying Diagnostic Operation System VAS 5051A "Channel X Reading And Testing", Set Value & Code Number

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Shown on VAS 5051 display:

"Channel 6, reading and testing" is shown in display field - 1 -.
The pad thickness values determined are shown in area - 2 -.
A slide bar with a code for current saved pad thickness appears in area - 3 -.

The pad thickness can change within the determined limits (3 to 14) via the slide bars.

NOTE:

If a pad thickness is entered using the slide bar that lies outside the determined thresholds, this is shown but not implemented.
If a pad thickness that is too large or too small is entered via the slide bar, the display resets itself.

Entry can also be done using keypad.

Fig 25: Identifying Diagnostic Operation System VAS 5051A "Channel X Reading And Testing", Set Value & Code Number

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Press button - 4 - (to enter via keypad).

Fig 26: Identifying Diagnostic Operation System VAS 5051A (Prompt For Entering Display Group Appears In Display Zone & Input Keypad Appears In Display Zone)

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Shown on VAS 5051 display:

The display "Enter adaptation value entry value: 0 to 65535" appears in display field - 1 -.
An entry keypad is shown in display field - 2 -.

Enter previously measured pad thickness via entry keypad in display field - 2 - and confirm by pressing Q button.

Fig 27: Identifying Diagnostic Operation System VAS 5051A "Channel X Reading And Testing", Set Value & Code Number

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Shown on VAS 5051 display:

The new pad thickness value entered appears in area - 3 - above slide bar.

Save new pad thickness by pressing button - 5 -.

Fig 28: Identifying Diagnostic Operation System VAS 5051A Display "Store Channel X", Original/New Code Number & New Value For Adaptation Channel

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Shown on VAS 5051 display:

Display "Save channel 6" appears in display field - 1 -.
The pad thickness values determined are shown in area - 2 -.
The original and new pad thickness value entered appears in area - 3 -.

Implement and save new pad thickness by pressing button - 4 -.

Display "Save channel 6 value 0 to 23 " appears in display field - 1 -.

End OBD and switch ignition off.
Install wheels → 44 - Wheels, Tires and Wheel Alignment
Check brake fluid level, and fill if necessary.