Brake Caliper Piston, Removing And Installing, FN 3: Installing

WARNING: This page is about a different variant/trim than selected.

Install in reverse order of removal. Note the following:

Cleaning:

WARNING:

Do not blow the brake system using compressed air, the dust produced is harmful to health!

Only Use Mineral Spirits for Cleaning the 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 on the piston and the seal before installing.

-- Insert the seal in brake caliper.

-- Insert the cap -A- in the tool.

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 2: Identifying Protective Cap & Piston Resetting Tool T10145

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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: Blowing Compressed Air Into Protective Cap

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

2 - : 3409

Do Not Tilt the Piston to Avoid Damaging the Sealing Boot.

-- Blow compressed air on the cap (maximum 3 bar (43.5 psi)) -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.

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