Front

Exploded View Of Lucas/Girling Front Caliper:

Component Notes And Information

NOTE:
^ Suring service procedures, refer to the illustration above and the information below.
^ When repairing, apply a thin coat of brake fluid to cylinders, pistons and seals. Install all parts in repair kit
^ During removal and installation procedures, refer to the component location illustration above and component notes below

1 Protective cap
2 Bleeder valve
- Before tightening lubricate threads lightly with brake fluid
3 Brake caliper housing
4 Self-locking hex bolt
- Tighten to: 35 Nm (26 ft lb)
- Always replace
- Counterhold guide bolts when loosening/tightening
5 Seal
- Remove using a suitable blunt tool
6 Piston
- Coat lightly with brake fluid or brake cylinder paste before installing
7 Protective seal
- Do not damage when inserting piston
8 Brake carrier with guide pins and protective caps
- Supplied as replacement part with pre-lubricated guide bolts and protective caps.
- If protective caps or guide bolts are damaged, install repair kit and lubricate guide bolts with grease pack supplied.


Removal

Caliper Piston Removing:

1. Force piston out of caliper housing with compressed air.

CAUTION: Place a wooden block in the caliper to prevent damage to the piston.

WARNING: Use only enough air pressure to force the piston out.

Caliper Seal Removing:

2. Carefully remove piston seal using VAG 1474/5.

CAUTION: When removing, use care to ensure that the cylinder bore is not damaged.

Installation

Piston Dust Seal Installing:

1. Install dust cap onto piston.
2. Install new piston seal into housing.

Piston Into Caliper Installing:

3. Lubricate piston and cylinder bore lightly with brake fluid.
4. Hold piston in front of caliper housing and push inner sealing lip into cylinder groove using VAG 1474/5.

Piston Into Caliper Pressing:

5. Press piston into caliper housing.
6. Outer lip of dust boot must slip into groove in piston.