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”,

page 98

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‐

ling. Refer to 

⇒ “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.