Volkswagen Workshop Service and Repair Manuals > Golf Mk2 > Running gear | Brakes, hydraulics, regulator, servo | Repairing front brake caliper, brake caliper VW II

Repairing front brake caliper, brake caliper VW II

Note

t	Install complete repair kit during repairs.

t	Apply thin coat of brake cylinder paste to brake cylinder, piston and oil seal.

1 -	Protective cap

q	Placing onto piston → Fig..

q	Inserting into cylinder groove → Fig..

2 -

Piston

q	Removing → Fig.

q	Positioning protective cap → Fig..

q	Installing → Fig. and → Fig.

q	First coat the piston lightly with brake cylinder paste.

3 -	Brake caliper housing

4 -

Oil seal

q	Remove with a plastic wedge → Fig..

Removing the piston

–	Blow compressed air through brake hose connection -arrow- to force out of brake caliper housing. Place a piece of wood in shaft to prevent damage to piston.

Taking out sealing ring

Use reworked wedges -V.A.G 1474/5- to do this.

Note

Reworking wedges -V.A.G 1474/5- → Fig.

Place protective seal with outer sealing lip on piston.

Insert inner sealing lip of protective cap into grove in cylinder.

Use reworked wedges -V.A.G 1474/5- to do this.

Hold piston in front of brake caliper housing and ensure that protective cap is not damaged.

Note

Reworking wedges -V.A.G 1474/5- → Fig.

Pressing piston with piston resetting tool into brake caliper housing

Note

The outer sealing lip of the protective cap will then lock in the groove on piston.

Reworking wedges -V.A.G 1474/5-

–	Grind tip of wedge in area -a- at sides as shown in illustration, observing width -b- (6 mm).

–	Grind tip of wedge to length -c- (10 mm).

–	Deburr reworked tip of wedge.

Volkswagen Workshop Service and Repair Manuals