Brake Caliper Piston, FN 3: Installing

Install in reverse order of removal. Note the following:

Cleaning:

Use only appropriate solvents for cleaning brake system.

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

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

-- Install sealing ring in brake caliper.

-- Install the cap -A- into the tool.

Fig 1: Identifying Protective Cap And Assembly Tool T 10146/6

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Piston Resetting Tool - Cap /6 T10146/6

-- Press the cap onto the brake caliper so that it is touching the brake caliper all the way around.

Fig 2: Identifying Protective Cap T10146/1 & Piston Resetting Tool T10145

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Piston Resetting Tool - Cap /6 T10146/6
2. Piston Resetting Tool T10145

Make sure the cap fits correctly:

Fig 3: Checking Seating Of Protective Caps

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- It must not be possible to pull the cap off the brake caliper by hand.

-- Gently push the piston on the cap.

-- Lock the piston in this position.

Fig 4: Pressing Piston Lightly Against Protective Cap And Lock It Into Position With Trim Removal Wedge

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

2 -

Trim Removal Wedge 3409

Do not tilt the piston in order to avoid damaging the sealing boot.

-- Blow compressed air on the cap (maximum 3 bar) -1-. This will force the cap onto the piston.

-- Push the piston into the brake caliper.

Fig 5: Identifying Piston Pressed Into Brake Caliper Using Piston Resetting Tool

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Piston Resetting Tool T10145

The outer seal lip of the cap thereby slips into the groove on the piston.

-- Install the brake caliper. Refer to BRAKE CALIPER, BRAKE CALIPER FN3 .