Removing and installing brake caliper piston (1ZG): Audi A1

🧭 Before you start

Fits: Audi A1 (8X, 2010–2018)

• Opens: brake fluid

Don't miss

• Take care not to damage paint coating on brake caliper.Take care not to damage cylinder surface.
• Install all parts supplied in repair kit.Use only methylated spirits to clean the brake components.The brake caliper must be replaced if the brake caliper piston or piston bore is damaged.
• The surfaces of the brake caliper piston and seal must be cleaned only with methylated spirits and then dried.
• When doing this hold piston in front of brake caliper.Do not damage seal when inserting piston.
• Risk of damage to protective cap and seal.Take care to keep brake caliper piston straight. — Press brake caliper piston lightly into cylinder by hand.

📋 Procedure

1. Remove brake pads .
2. Remove brake caliper and disconnect from hydraulic system .
3. Clamp brake caliper in jaws of vice. Use protective jaw covers. [Note: Take care not to damage paint coating on brake caliper.Take care not to damage cylinder surface.]
4. ⚠ Risk of injury.Wear safety goggles.When pressing out brake caliper piston, DO NOT reach into brake caliper with your fingers.Place a cloth over bore in brake caliper to catch any brake fluid spatter. Wrap another cloth tightly around nozzle of compressed-air gun applied to brake caliper.Always wear chemical-resistant protective gloves to prevent brake fluid from contacting skin. — Place a piece of wood in the caliper to prevent damage to the piston when it is forced out.
5. Apply compressed air nozzle to threaded hole for brake hose (arrow) and press piston out of caliper.

6. Lever protective cap off brake caliper using removal wedge3409.
7. Remove seal using removal wedge3409. [Note: Install all parts supplied in repair kit.Use only methylated spirits to clean the brake components.The brake caliper must be replaced if the brake caliper piston or piston bore is damaged.]
8. The surfaces of the brake caliper piston and seal must be cleaned only with methylated spirits and then dried.
9. Apply thin coat of lithium grease to brake caliper piston and seal Electronic parts catalogue.
10. Insert seal into brake caliper.
11. Place outer sealing lip of protective cap on brake caliper piston.
12. Using removal wedge3409, insert inner sealing lip into groove of cylinder. [Note: When doing this hold piston in front of brake caliper.Do not damage seal when inserting piston.]
13. ⚠ Risk of damage to protective cap and seal.Take care to keep brake caliper piston straight. — Press brake caliper piston lightly into cylinder by hand.
14. Press piston into brake caliper using piston resetting tool T10145.
15. Install brake caliper .
16. Install brake pads .

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