Front brake caliper piston, removing and installing

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required

Removing

Fig 2: Using Compressed Air To Force Piston Out Of Brake Caliper Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

Fig 3: Removing Seal With Trim Removal Wedge 3409

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

Installing

The surface of the piston and seal should be cleaned using methylated spirits and then dried.
Apply a thin coat of lithium grease G 052 150 A2 to piston and seal before inserting.

Fig 4: Installing Sealing Ring In Brake Caliper

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert inner seal in brake caliper housing groove using trim removal wedge 3409.

Fig 5: Pressing Protective Cap With Assembly Tool And Piston Resetting Tool Into Brake Caliper

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

Fig 6: Pushing Protective Seal Onto Brake Caliper Housing So That It Lies Against Housing All Round

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Push protective seal onto brake caliper housing so that it lies against the housing all round.
It should not be possible to remove the protective seal from the brake caliper housing by hand.
Apply a thin coat of lithium grease G 052 150 A2 to piston and seal before inserting.

Fig 7: Lifting Up Piston With Standard Extension And Ratchet Attachment

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Lift up piston with standard extension and ratchet attachment as shown in illustration and press lightly onto protective cap.

NOTE:

Inflate protective cap with compressed air (maximum 3 bar). The protective cap will then locate around the brake piston.

Use jaw protectors

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