Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 791
♦ Brake Servo Release Tool - T10159A-
♦ Brake Caliper Tool - T10165-
♦ Torque Wrench 1783 - 2-10Nm - VAG1783-
♦ Brake Pedal Actuator - VAG1869/2- .
♦ Trim Removal Wedge - 3409-
47 – Hydraulic Components
1
Front Brake Caliper
⇒ “1.1 Overview - Front Brake Caliper”, page 97
⇒ “1.2 Brake Caliper Piston, Removing and Installing”,
1.1
Overview - Front Brake Caliper
1 - Dust Cap
❑ Install onto bleeder
valve
2 - Bleeder Valve
❑ 10 Nm
❑ Apply a thin coat of As‐
sembly Paste - G 052
150 A2- to the threads
before screwing in.
3 - Hex Bolt
❑ 35 Nm
❑ Replace after removing
4 - Guide Pin
5 - Cap
❑ Lubricate the groove
with the grease that
comes with the repair kit
and then install the cap
into the groove on the
brake carrier and the
guide pin.
6 - Brake Carrier
❑ Is assembled with the
guide pins and cap as
well as with sufficient
grease on the guide
pins.
❑ If protective caps or
guide pins are damaged
use repair kit. Use sup‐
plied grease packet to
lubricate guide pins.
7 - Cap
❑ Removing and instal‐
⇒ “1.2 Brake Caliper Piston, Removing and Installing”, page 98
❑ Do not damage when installing piston
8 - Piston
❑ Removing and installing. Refer to
⇒ “1.2 Brake Caliper Piston, Removing and Installing”, page 98
❑ Apply thin coat of Assembly Paste - G 052 150 A2- to piston before inserting
9 - Seal
❑ Removing and installing. Refer to
⇒ “1.2 Brake Caliper Piston, Removing and Installing”, page 98
10 - Brake Caliper
1.2
Brake Caliper Piston, Removing and In‐
stalling
Special tools and workshop equipment required
♦ Trim Removal Wedge - 3409-
♦ Piston Resetting Tool - T10145-
Removing
– Force piston from brake caliper using compressed air.
Place a wooden board into the recess of the caliper housing so it
is not damaged.
– Remove seal with Trim Removal Wedge - 3409- .
When removing, make sure that surface of cylinder is not dam‐
aged.
Installing
– Clean the surfaces on the pistons and seal with mineral spirits.
– Apply a thin coat of installation paste G 052 150 A2 on the
piston and the seal before installing.
– Insert oil seal into brake caliper.
– Place the cap with the outer sealing lip on the piston.
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