VW Golf manuals

Volkswagen Golf Service & Repair Manual: Removing and installing brake caliper PC57

Special tools and workshop equipment required
   
Removal wedge -3409-
 

Removing and installing brake caliper PC57

Piston resetting appliance -T10145-
Removing
–  Press piston out of brake caliper using compressed air.
 

Removing and installing brake caliper PC57

Place a piece of wood in the recess to prevent damage to the piston.
 

Removing and installing brake caliper PC57

–  Remove seal using wedge 3409.
When removing ensure that the surface of the cylinder is not damaged.
Installing
Install in reverse order of removal, observing the following:
–  The surfaces of the piston and seal must be cleaned only with methylated spirits and then dried.
–  Apply a thin coat of assembly paste G 052 150 A2 to piston and seal before inserting.
–  Insert seal in brake caliper.
 

Removing and installing brake caliper PC57

–  Place protective cap with outer sealing lip on piston.
 

Removing and installing brake caliper PC57

–  Insert inner sealing lip into groove in cylinder using wedge 3409.
When doing this, hold piston in front of brake caliper.
 

Removing and installing brake caliper PC57

–  Press piston into brake caliper using piston resetting appliance.
The outer sealing lip on the protective cap will then slip into the piston groove.
 

Removing and installing brake caliper PC57

Assembly overview - brake caliper (PC57 brakes)
When carrying out repairs, install all parts supplied in repair kit. Use only methylated spirits for cleaning the brake. Apply thin coat of lithium grease -G 0 ...

Rear brake caliper
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Other materials:

Overview of fitting locations - fuel supply system, Golf Variant
  Note Fuel lines are secured with O-type clips. These O-type clips must always be renewed every time they are removed. Start engine if fuel tank was empty. Then start the auxiliary heater repeatedly until the heater d ...

Wheel change, protecting wheel centring seat against corrosion
Applies to alloy and steel wheels When changing a wheel, wheel centring seat should be waxed using wax spray to prevent corrosion between wheel centring seat and wheel rim → Electronic Parts Catalogue “ETKA”. ...

Checking colour indicator, “3-colour”
  WARNING Danger of injury! Observe warning notices and safety regulations → Chapter! General information about colour indicator: Applies fo ...

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