Brake Calipers - Repairing
86VW2Applies To
SCIROCCO 16 V
1986
Group
47
Subject
Front and Rear Brakes
Part Identifier N/A
Key Points
Brake calipers, repairing
A233
Number
86-03
June 17, 1986
Front brakes
FIGURE 1 - PISTON, REMOVING:
- blow out with compressed air
CAUTION
Place wooden block in cylinder housing to prevent damage to piston. Use only enough air pressure to force piston out.
FIGURE 2 - PISTON SEAL, REMOVING:
- carefully pry out seal with screwdriver
FIGURE 3 - PISTON, INSTALLING:
- slide dust boot onto piston
FIGURE 4 - PISTON, INSTALLING:
- lubricate piston and cylinder bore lightly with brake cylinder paste
- install piston and inner lip of dust boot into groove in brake cylinder
FIGURE 5 - PISTON, INSTALLING:
- press piston in as far as possible; outer lip of boot will slip into piston groove
Rear brakes
CAUTION
New brake calipers are filled with brake fluid and pre-bled.
During repairs, the brake calipers MUST be bled before installing on vehicle. (see Fig. 6)
Use all parts in repair kit.
FIGURE 1 - PISTON, REMOVING:
- unscrew piston from caliper cylinder with hexagon wrench
FIGURE 2 - PISTON SEAL, REMOVING:
- pry out carefully to avoid damaging piston bore
FIGURE 3 - DUST CAP FOR PISTON, INSTALLING:
- slide outer lip onto piston
Note
If either piston or bore in brake caliper are corroded, pitted or scored, affected part must be replaced.
FIGURE 4 - PISTON, INSTALLING:
- lubricate piston and cylinder bore lightly with brake cylinder paste
- insert inner lip of dust cap into groove of brake cylinder
Note
Hold piston by hand against brake caliper housing while inserting dust cap into cylinder groove.
FIGURE 5 - PISTON, INSTALLING:
- press piston down while screwing in as far as possible
CAUTION
Outer lip of dust cap must slip into groove of piston.
FIGURE 6 - REAR BRAKE CALIPER, PRE-BLEEDING:
- place caliper in position shown
- open bleeder valve and fill with brake fluid from bleeder container until fluid flows from brake hose connection (arrow) without bubbles
- close bleeder valve