FNR-G60

Front brake caliper piston, removing and installing





Special tools, testers and auxiliary items required

^ Torque wrench V.A.G 1331
^ Torque wrench V.A.G 1332
^ Piston resetting tool T10145
^ Trim removal wedge 3409
^ Assembly tool for protective caps T10146/5
^ Lithium grease G 052 150 A2

Removing





- Use compressed air to force piston out of brake caliper housing.

Note:
^ Place a piece of wood in the recess to prevent damaging the piston.





- Remove seal.
- Use trim removal wedge 3409 for this.

Note:
^ When removing make sure that the surface of the cylinder is not damaged.

Installing

- The surface of the piston and seal should be cleaned using methylated spirits and then dried.
- Apply a thin coat of lithium grease G 052 150 A2 to piston and seal before inserting.





- Insert inner seal in brake caliper housing groove using trim removal wedge 3409.





- Press in protective cap with special tool -1- and -2-.
- Item -1- Assembly tool for protective caps T10146/1
- Item -2- Piston resetting tool T10145

Note:
^ Use jaw protectors





- Push protective seal onto brake caliper housing so that it lies against the housing all round.
- It should not be possible to remove the protective seal from the brake caliper housing by hand.
- Apply a thin coat of lithium grease G 052 150 A2 to piston and seal before inserting.





- Lift up piston with standard extension and ratchet attachment as shown in illustration and press lightly onto protective cap.

Note:
^ Make sure not to tilt piston to avoid damage to the seal.

- Inflate protective cap with compressed air (maximum 3 bar). The protective cap will then locate around the brake piston.

Use jaw protectors

- Press piston into brake caliper housing by hand.

Note:
^ The protective seal inner sealing lip will then locate in the piston groove.