Special tools and workshop equipment required

• Wedge - 3409-

• Opening/closing wrench - T10165-

Note

• Other than removal and installation of the brake calliper piston, no repairs are permitted on the brake calliper.
• When carrying out repairs, install all parts supplied in repair kit.
• Use only methylated spirits for cleaning the brake.
• New brake calipers are filled with brake fluid and are pre-bled.
• Apply thin coat of assembly paste G 052 150 A2 to brake cylinder, piston and sealing ring.

Removing:

• Fit the wrench open / closed - T10165- on the brake calliper housing piston.
• Extract the piston from the brake calliper housing by turning the handle on the tool to the left.
• If the piston will not move easily, a 13 mm open-end spanner can be applied at the flats provided -arrow A-.

• Remove seal using wedge - 3409- .

Installation:

• The piston and join ring surfaces can only be cleaned using alcohol and immediately dried.
• Before fitting the piston and seal ring, apply a thin coating of assembly paste.
• Introduce the join ring into the brake caliper housing.

• Fit the protective hood with the outer sealing lip over the piston.

• Using the removal wedge - 3409- , insert the inner sealing lip into the groove of cylinder.

Note During this operation, the piston has to be supported in front of the brake caliper housing.

• Fit the wrench open / closed - T10165- on the brake calliper housing piston.
• In order to turn the piston, use the disc - T10165/1- .
• Fit the piston to the brake calliper housing by turning the handle on the tool to the right.

Note

• Insert piston compressing tool (make sure that the collar contacts the brake caliper).
• If the position of the piston is modified with the open/close wrench - T10165- then the automatic readjustment of the brake calliper will be broken.

• Fit the brake pads.

Pre-bleeding brake caliper:

• Open the air purge screw -arrow A- and, using the brake fluid collection flask, fill the brake fluid up to a point where fluid without bubbles comes out of the screw hole (connection for the brake hose) -arrow B- .
• Close bleeder valve.

Note For the initial purge, fit the brake calliper as shown in the illustration.