Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 793
❑ Check for damage and correct seating
10 - Brake Carrier
❑ Supplied as an assembled replacement part with sufficient grease on guide pins
❑ If protective caps or guide pins are damaged use repair kit. Use supplied grease packet to lubricate guide
pins
2.2
Brake Caliper Piston, Removing and In‐
stalling
⇒ “2.2.1 Brake Caliper Piston, Removing and Installing”,
page 103
⇒ “2.2.2 Brake Caliper, Pre-Bleeding”, page 105
2.2.1
Brake Caliper Piston, Removing and In‐
stalling
Special tools and workshop equipment required
♦ Brake Caliper Tool - T10165-
♦ Trim Removal Wedge - 3409-
Removing
WARNING
Adjust the brake piston is permitted only with the Brake Caliper
Tool - T10165- .
– Install the Brake Caliper Tool - T10165- so that the collar
touches the piston.
– Remove piston from brake caliper by turning knurled wheel
toward left.
– For pistons that are difficult to move, an open-end wrench (size
13 mm) can be applied at the appropriate wrench surface
-arrow A-.
– Remove the sealing ring using the Trim Removal Wedge -
3409- .
Installing
Install in reverse order of removal. Note the following:
Note
♦
Install complete repair kit when servicing.
♦
Only use mineral spirits to clean brake parts.
♦
New brake calipers are filled with brake fluid and are pre-bled.
♦
Apply thin coat of Assembly Paste - G 052 150 A2- to brake
cylinders, pistons and seals.
♦
In case of repair, brake calipers must always be pre-bled be‐
fore being installed into vehicle (without brake pads). Refer to
⇒ “2.2.2 Brake Caliper, Pre-Bleeding”, page 105
.
– Clean the surfaces on the pistons and seal only with mineral
spirits and then dry.
– Place the sealing ring in the groove.
– Apply a thin coat of Assembly Paste - G 052 150 A2- on the
piston and the seal before installing.
– Place the cap with the outer sealing lip on the piston.
– Insert inner sealing lip in cylinder groove with Trim Removal
Wedge - 3409- .
– Hold piston in front of brake caliper for this procedure.
– Install the pistons by turning clockwise.
– Be careful not to damage the cap.
– Use the Resetting & Extracting Tool - Plate - T10165/1- to help
you bolt it on.
– Install the Brake Caliper Tool - T10165- so that the collar on
the Resetting & Extracting Tool - Plate - T10165/1- is touching.
– Install by turning the thumbwheel on the Brake Caliper Tool -
T10165- clockwise.
The automatic adjustment in brake caliper is destroyed when pis‐
ton is moved with piston resetting tool (for example T 10145) or
foot brake is pressed.
2.2.2
Brake Caliper, Pre-Bleeding
– Open the bleeder valve -arrow A- and using a standard bleed‐
er bottle, fill with brake fluid until brake fluid with no bubbles
flows from the threaded hole (brake hose connection)
-arrow B-. Close the bleed valve.
Position brake caliper as shown during pre-bleed procedure.
3
Brake Booster/Brake Master Cylin‐
der
⇒ “3.1 Overview - Brake Booster/Brake Master Cylinder”,
page 106
⇒ “3.2 Brake Lamp Switch, Removing and Installing”, page 108
⇒ “3.3 Brake Master Cylinder, Removing and Installing”,
page 110
⇒ “3.4 Brake Booster, Removing and Installing”, page 113
⇒ “3.5 Brake Fluid Reservoir, Removing and Installing”,
3.1
Overview - Brake Booster/Brake Master Cylinder
WARNING
Only use new brake fluid conforming to VW standard (VW 501
14).
1 - Hex Nut
❑ 25 Nm
❑ Self-locking
❑ Replace after removing
❑ Tightening sequence.
Refer to
2 - Bracket/Pedal Assembly
❑ Assembly sequence.
Refer to
.
❑ Mounting bracket, re‐
moving and installing.
Refer to
.
❑ Separate the brake ped‐
al from brake booster.
Refer to
❑ Brake pedal to brake
booster, connecting.
Refer to
.
❑ Brake Pedal, removing
and installing. Refer to
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