Front Caliper Piston FN 3

Special tools and workshop equipment required

Removing

-- Force piston from brake caliper using compressed air -arrow-.

Fig 1: Identifying Brake Caliper Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Place a wooden board into the recess of the caliper housing so it is not damaged.

-- Pry off protective cap from brake caliper using 3409.

Fig 2: Identifying Protective Cap Pried Off From Brake Caliper With Trim Removal Wedge 3409

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-- Remove seal using 3409.

Fig 3: Identifying Removal Of Brake Caliper Seal With Wedge 3409

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When removing, make sure that surface of cylinder is not damaged.

Installing

-- The surface of the piston and seal must only be cleaned with mineral spirits and then dried.

-- Thinly coat piston and seal with assembly paste G 052 150 A2 before inserting.

-- Install sealing ring in brake caliper.

-- Insert protective cap -A- into T10146/6 -1-.

Fig 4: Identifying Protective Cap And Assembly Tool T10146/6

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-- Press protective cap onto brake caliper using assembly tool -1- and T10145 -2- so that it makes contact all around on brake caliper.

Fig 5: Identifying Protective Cap T10146/1 & Piston Resetting Tool T10145

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Check Seating of Protective Caps

Fig 6: Identifying Protective Cap

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-- Protective cap must no longer be able to be pulled from brake caliper by hand.

-- Press piston lightly onto protective cap and then secure it in this position using e.g. 3409 -2-.

Fig 7: Pressing Piston Lightly Against Protective Cap And Lock It Into Position With Trim Removal Wedge

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Do not angle piston, to avoid damaging the seal sleeve.

-- Blow compressed air (max. 3 bar) onto protective cap -1-. Protective cap springs onto piston.

-- Press piston into brake caliper using piston resetting tool -1-.

Fig 8: Identifying Piston Pressed Into Brake Caliper Using Piston Resetting Tool

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Outer sealing lip of protective cap will then engage in piston groove.