2. Clamp the caliper in a vice, piston up.
3. Remove the piston dust cap from the groove in the caliper.
4. On a Teves caliper, place a flat in the jaws of the caliper against the piston, then use compressed air to blow the piston out of the bore. Apply air through the brake fluid inlet.
5. On the Girling caliper, use a socket wrench to unscrew the piston from the hole.
6. Remove the piston seal from the bore being careful not to scratch the bore surface. Remove the dust cap from the piston.
7. Turn off the pumping union.
8. Clean all parts with methanol and let dry.
9. Check up a condition of a surface of the piston and an aperture. Check the auto adjuster thread. Check the caliper housing for signs of fluid leakage around the handbrake control lever. Check for wear on guide pins, seals and bushings. Replace parts as needed. On the Girling caliper, the suspension frame, along with the guide pins, is already lubricated.
10. If the caliper and piston are in good condition, prepare a seal repair kit and brake cylinder paste.
11. Apply paste to bore and piston surfaces.
12. Position the piston seal in the bore groove.
13. To install the piston on the Teves caliper, first push the clamps into the caliper up to the stop using a screwdriver. Place the dust cap on the smooth end of the piston, then place the piston against the caliper, turn it slightly to engage the threads. Use a screwdriver to lift the dust cap into the groove in the caliper. Press the piston all the way into the hole, making sure it goes straight in and does not damage the auto adjuster. To perform this operation, the Audi tool shown in Figure 9.20 is used. A G-clamp can also be used for this purpose. Once the piston enters the bore, the dust cap will snap into place in the groove on the outer end of the piston.
14. To install the piston on the Girling caliper, place the dust cap on the smooth end of the piston, then place the piston against the caliper. Use a screwdriver to lift the dust cap into the groove in the caliper. Use a socket wrench to screw the piston into the hole. The dust cap will snap into the groove on the outer end of the piston.
15. Install a new rubber cap on the bleeder port. Apply paste to the threads, then clamp the bleeder screw into the caliper.
16. The new Girling calipers are already filled with brake fluid. Audi also recommends filling and bleeding the Girling caliper after a rebuild. A similar procedure can also be performed on Teves calipers.
17. Clamp the caliper in a vise, inlet up. Loosen the bleeder screw and connect the brake fluid supply hose to it. Fill the caliper until there are no air bubbles in the fluid, then tighten the bleed screw. Seal the inlet if necessary.
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