Audi Workshop Service and Repair Manuals

Removing and installing piston for front brake caliper

Special tools and workshop equipment required

t	Torque wrench -V.A.G 1331-

t	Torque wrench -V.A.G 1332-

t	Piston resetting appliance -T10145-

t	Removal wedge -3409-

t	Assembly tool for protective caps -T10146/5-

t	Lithium grease -G 052 150 A2-

Removing

–  Force piston out of brake caliper housing using compressed air.   Note Place a piece of wood in the recess to prevent damaging the piston.

–  Take out seal. –  To do so, use removal wedge -3409-.   Note When removing ensure that the bore of the cylinder is not damaged. Installing –  The surface of the piston and seal should be cleaned using only methylated spirits and then dried. –  Apply a thin coat of lithium grease -G 052 150 A2- to piston and seal before inserting.

–  Insert inner seal into groove of brake caliper.

–  Press in protective cap with special tool -1- and -2-. –  Item -1-: Assembly tool for protective caps -T10146/1- –  Item -2-: Piston resetting appliance -T10145- Use jaw protectors

–  Push protective cap onto brake caliper housing and press it in so that it is seated flush -arrow-. –  At this stage it should not be possible to remove the protective cap from the brake caliper housing by hand. –  Apply a thin coat of lithium grease -G 052 150 A2- to piston and seal before inserting.

–  Lift up piston with standard extension and ratchet attachment as shown in illustration and press lightly onto protective cap. Keep the piston straight to avoid damaging the seal. –  Inflate protective cap with compressed air (maximum 3 bar). The protective cap will then locate around the brake piston. Use jaw protectors –  Press piston into brake caliper housing by hand.   Note The inner sealing lip on the protective cap will then locate in the piston groove.