Volkswagen Workshop Service and Repair Manuals

Repairing rear brake caliper

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

t	When carrying out repairs install all parts supplied in repair kit.

t	New brake calipers are filled with brake fluid and are pre-bled.

t	When carrying out repairs it is essential to appropriately pre-bleed the brake calipers (without brake pads) before installing in the vehicle → Fig..

1 -	Self-locking bolts, 35 Nm

q

Renew.

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

2 -

Oil seal

q	Remove with a plastic wedge → Fig..

3 -	Piston with automatic adjustment

q	Remove from brake caliper housing:

q	Vehicles up to 07.87 → Fig..

q	Vehicles as of 08.87 → Fig..

q	Installing into brake caliper housing → Fig..

4 -	Protective cap

q	Position with outer sealing lip onto piston → Fig..

q	Insert with inner sealing lip into groove in brake caliper housing → Fig..

q	Do not damage sealing lips when positioning or inserting.

5 -

Dust cap

6 -	Bleed valve

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

7 -	Brake caliper housing with lever for handbrake cable

q	If a leak exists at the handbrake cable lever, renew brake caliper housing.

q	After repairing, pre-bleed brake caliper housing → Fig.

8 -

Guide pin

q	Lubricate before installing protective cap

9 -	Protective cap

q	Insert onto brake carrier and guide pin

10 -	Brake carrier with guide pin and protective cap

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 piston from brake caliper housing, vehicles up to 07.87 –  Unscrew piston by turning anti-clockwise.

Removing piston from brake caliper housing, vehicles as of 08.87 –  Unscrew piston by turning anti-clockwise.

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.

Inserting inner sealing lip of protective cap into grove in brake caliper housing Use reworked wedges -V.A.G 1474/5- to do this. When doing this hold piston in front of caliper housing.   Note Reworking wedges -V.A.G 1474/5- → Fig.

Installing piston into brake caliper housing –  Screw piston in to stop by turning clockwise. Press firmly onto piston while screwing it in. –  In vehicles as of 08.87, use tool -3131- instead of Allen key → Fig.   Note The outer sealing lip of the protective cap will then lock in the groove on piston.

Pre-bleeding brake caliper –  Open bleed valve and fill with brake fluid using a standard bleed bottle until brake fluid flows out of the threaded hole (brake hose connection) without bubbles. Close bleed valve.   Note Position brake caliper as illustrated to pre-bleed.