Volkswagen Workshop Service and Repair Manuals

Repairing Girling front brake calipers

(For vehicles with 79 kW as of 08.88 and for vehicles with 95, 102 and 118 kW)

t	Install complete repair kit during repairs.

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

1 -

Dust cap

q	Fit onto bleed valve

2 -	Bleed valve

q	Apply thin coat of brake cylinder paste to threads before screwing in.

3 -	Brake caliper housing

4 -	Self-locking bolts, 35 Nm

q

Renew.

q	When loosening and tightening, counter hold on guide pin.

5 -

Oil seal

q	Remove with a plastic wedge → Fig..

6 -

Piston

q	Removing → Fig.

q	Positioning protective cap → Fig..

q	Installing → Fig. and → Fig.

q	First coat the piston lightly with brake cylinder paste.

7 -	Protective cap

q	Placing onto piston → Fig..

q	Inserting into cylinder groove → Fig..

8 -	Brake carrier with guide pins and protective caps

q	Supplied as replacement part, assembled with sufficient grease on guide pins.

q	If protective caps or guide pins are damaged, install repair kit. Use grease sachet supplied to lubricate guide pins.

Removing the piston –  Blow compressed air through brake hose connection 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.