Brake Caliper Piston, CI 38 Rear Brakes: Installing

WARNING: This page is about a different car, the 2016 Volkswagen Beetle, 2015 Volkswagen Beetle, 2014 Volkswagen Beetle, 2013 Volkswagen Beetle, and 2012 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

Install in reverse order of removal. Note the following:

NOTE:

Install complete repair kit when servicing.

Only use mineral spirits to clean brake parts.

New brake calipers are filled with brake fluid and are pre-bled.

Apply thin coat of Assembly Paste G 052 150 A2 to brake cylinders, pistons and seals.

In case of repair, brake calipers must always be pre-bled before being installed into vehicle (without brake pads). Refer to BRAKE CALIPER, PRE-BLEEDING .

-- Clean the surfaces on the pistons and seal only with mineral spirits and then dry.

-- Place the sealing ring in the groove.

-- Apply a thin coat of Assembly Paste G 052 150 A2 on the piston and the seal before installing.

-- Place the cap with the outer sealing lip on the piston.

Fig 1: Identifying Protective Seal With Outer Sealing Lip On Piston

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Insert inner sealing lip in cylinder groove with Trim Removal Wedge 3409.

Fig 2: Identifying Inner Sealing Lip Inserted Into Groove In Cylinder Using Wedge 3409

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Hold piston in front of brake caliper for this procedure.

-- Install the pistons by turning clockwise.

Fig 3: Identifying Thumbwheel On T10165

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Be careful not to damage the cap.

-- Use the Resetting & Extracting Tool - Plate T10165/1 to help you bolt it on.

-- Install the Brake Caliper Tool T10165 so that the collar on the Resetting & Extracting Tool - Plate T10165/1 is touching.

-- Install by turning the thumbwheel on the Brake Caliper Tool T10165 clockwise.

The automatic adjustment in brake caliper is destroyed when piston is moved with piston resetting tool (for example Piston Resetting Tool T10145) or foot brake is pressed.