Volkswagen Workshop Service and Repair Manuals

Removing:

• ‒ → Screw piston out of brake caliper housing by turning the knurled wheel anti-clockwise.

Notes:

• ◆ If piston is difficult to move, use a 13 mm AF open jaw spanner on the flats (arrow A) provided for this purpose.
• ◆ Fit special tool 3272 so that the collar (arrow) is before the piston.

• ‒ → Take out seal.
• ‒ Use modified wedge V.A.G 1474/5 to do this =>Page 47-41.

Note:

Ensure that the surface of the cylinder is not damaged during removal.

Modifying wedge V.A.G 1474/5

• ‒ Reshape wedge point size in area -a- as per illustration observing width -b- (6 mm).
• ‒ Reshape wedge point to length -c- (10 mm).
• ‒ Remove burrs from modified wedge point.

Installing:

• ‒ → Place protective seal with the outer sealing lip on the piston.

• ‒ → Using a plastic wedge, insert the inner sealing lip into the cylinder groove.

Note:

When doing this hold piston in front of brake caliper housing.

• ‒ → Screw piston into housing by turning knurled wheel clockwise.

Notes:

• ◆ Fit special tool 3272 so that the collar (arrow) of the tool is seated against the brake carrier.
• ◆ If piston is difficult to move, use a 13 mm AF open jaw spanner on flats (arrow A) provided for this purpose.
• ◆ If the piston is pushed back with a piston resetting tool or by operating the foot brake the automatic adjustment in the brake caliper is destroyed.

• ‒ Fit brake pads.

Pre-bleeding brake caliper

• ‒ → Open bleed valve and using a standard bleeder bottle, fill with brake fluid until bubble-free brake fluid flows from the threaded hole (brake hose connection). Close bleed screw.

Note:

Position brake caliper as illustrated to pre-bleed.