1996 VOLKSWAGEN PASSAT display

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Front brake caliper pistons, removing
and installing

Removing Note:
Place a piece of wood in the recess to prevent
damaging the piston. - Force piston out of brake caliper housing using
compressed air. Note:
When removing ensure that the surface of the
cylinder is not damaged. - Remove seal with a screwdriver. Page 3 of 5Girling front brake caliper, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.2

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Installing - Place protective seal with the outer sealing lip on
the piston. Note:
Hold piston in front of caliper housing. - Using a screwdriver, insert the inner sealing lip into the cylinder groove. Page 4 of 5Girling front brake caliper, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.2

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Note:
The protective seal outer sealing lip will then locate in
the piston groove. - Press piston into the brake caliper housing using
piston resetting tool. Page 5 of 5Girling front brake caliper, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.2

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Front brake caliper,
servicing
(Teves/Ate)
Note: When repairing install all
parts supplied in repair kit. Apply thin coat of brake
cylinder paste to brake
cylinders, pistons and
seals.
1 - Protective seal Push onto bleed valve 2 - Bleed valve Apply thin coat of brake cylinder paste to threads before
threading in
3 - Cap Install in mounting
bushing
4 - Guide pin, 25 Nm (18 ft
lb)
5 - Mounting bushing Insert into brake
caliper housing Page 1 of 5Front brake caliper, servicing (Teves/Ate)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.3

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6 - Brake cylinder housing 7 - Brake carrier Install on brake caliper
housing
8 - Retaining spring Install with both ends
in the drillings in brake
caliper housing
9 - Piston seal Remove using a
screwdriver Fig. 2 10 - Piston Force piston out of
brake caliper using
compressed air Fig. 1 Installing Fig. 3 and
Fig. 4 and Fig. 5 First coat the piston
lightly with brake
cylinder paste. Piston diameter 54
mm
11 - Protective seal Do not damage when
installing piston Page 2 of 5Front brake caliper, servicing (Teves/Ate)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.3

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Note:
Place a piece of wood in the recess to prevent
damaging the piston. Fig. 1 Piston, pressing out of cylinder using
compressed air Fig. 2 Piston seal, removing Page 3 of 5Front brake caliper, servicing (Teves/Ate)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.3

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Fig. 3 Protective seal, installing Note:
Hold piston in front of caliper housing. Fig. 4 Protective seal, installing - Using a screwdriver, insert inner sealing lip into
cylinder groove Page 4 of 5Front brake caliper, servicing (Teves/Ate)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.3

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Note:
The protective seal outer sealing lip will then locate in
the piston groove. Fig. 5 Piston, installing Page 5 of 5Front brake caliper, servicing (Teves/Ate)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.3