2. Clamp the caliper in a vice, piston facing up.
3. Remove the piston dust cap from the groove in the caliper.
4. On a Teves caliper, place the die in the caliper jaws against the piston, then use compressed air to blow the piston out of the bore. Feed 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. Unscrew the bleed screw.
8. Clean all parts with methyl alcohol and let dry.
9. Check the condition of the piston surface and bore. Check the threads of the automatic adjuster. Check the caliper housing for signs of fluid leakage around the handbrake control lever. Check the wear of the guide pins, seals and bushings. Replace parts as necessary. On a Girling caliper, the suspension frame together with the guide pins is already lubricated.
10. If the caliper and piston are in good condition, prepare a repair kit of seals and paste for brake cylinders.
11. Apply the paste to the bore and piston surfaces.
12. Place the piston seal in the bore groove.
13. To install the piston on the Teves caliper, first press the clamp into the caliper until it stops, using a screwdriver. Place the dust cap on the smooth end of the piston, then place the piston on the caliper, turning it slightly so that the threads engage. 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 that it goes straight in and does not damage the automatic adjuster. The Audi tool shown in Fig. 9.20 is used for this operation. A G-clamp can also be used for this purpose. Once the piston is in the hole, the dust cap will snap into 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 position the piston on 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 nipple. Apply paste to the threads, then clamp the bleeder nipple into the caliper.
16. New Girling calipers are already filled with brake fluid. Audi also recommends filling and bleeding the Girling caliper after rebuilding. A similar procedure can also be performed on Teves calipers.
17. Clamp the caliper in a vice with the inlet hole facing up. Loosen the bleeder nipple and attach the brake fluid supply hose to it. Fill the caliper until the fluid is free of air bubbles, then tighten the bleeder nipple. Plug the inlet hole if necessary.
The original article is available on the website: AUDImanual.ru