Audi Workshop Service and Repair Manuals

Removing and installing piston for brake caliper (PR 1ZC) l  Brake caliper removed l  Remove brake caliper → Chapter. Special tools and workshop equipment required

t  Removal wedge -3409-

t  Piston resetting appliance -T 10145-

t  Assembly tool for protective caps -T10146/6- Removing

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

–  Lever off protective cap from brake caliper using removal wedge -3409-.

–  Remove seal using removal wedge -3409-. 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. –  Before installing, apply thin coat of lithium grease -G 052 150 A2- to piston and seal. –  Insert seal into brake caliper.

–  Fit protective cap -A- in assembly tool T10146/6 -1-.

–  Push protective cap onto brake caliper using assembly tool -1- and piston resetting appliance -2- so that it is seated on the brake caliper all round. Checking correct seating of protective cap:

–  At this stage it should not be possible to remove the protective cap from the brake caliper by hand. –  Press the piston lightly against the protective cap and lock in position (e.g. with assembly wedge -2-).

–  Inflate protective cap with compressed air (maximum 3 bar) -1-. The protective cap will then locate around the piston. Keep the piston straight to avoid damaging the sealing collar or the seal.

–  Press piston into brake caliper using piston resetting tool -1-. The outer sealing lip of the protective cap will then lock in the groove on piston. Install brake caliper → Chapter.