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Mechanical Components - Brake System: Overview Audi A3 8P facelift

Mechanical - Hydraulic 10 illustrations ~2466 words

BRAKES, FS III ASSEMBLY OVERVIEW

Note. To siphon off brake fluid from the brake fluid reservoir, use the brake filler/bleeder unit VAS 5234. Before removing a brake caliper or disconnecting a brake hose from a brake caliper, install the brake pedal actuator V.A.G 1869/2, to prevent the brake fluid reservoir from draining.

WARNINGAfter installing brake pads, depress brake pedal several times firmly to properly seat brake pads in their normal operating position.

Note. Install complete repair kit After replacing brake pads, depress brake pedal several times firmly to properly seat brake pads in their normal operating position. When siphoning brake fluid, always use a bleeder bottle that is used exclusively for brake fluid. Brake fluid is poisonous. NEVER siphon brake fluid with your mouth!

General notes BRAKES, FS III ASSEMBLY OVERVIEW

Scheme 1

Scheme 1
Scheme 1
  1. Bolt 10 Nm
  2. Brake Disc Allocation, dimensions, wear limits, refer to «BRAKES»(ref-496091-S32532055972012082100000) Remove brake caliper to remove Do not use excessive force to separate the brake rotor from the wheel hub. If necessary, use rust penetrant, otherwise the brake rotors could be damaged. Must always be replaced together on both sides of axle
  3. Bolt 4 Nm
  4. Brake Pads Pad thickness, wear limit, refer to «BRAKES»(ref-496091-S32532055972012082100000) Checking brake pad thickness, refer to «BRAKE PADS, CHECKING THICKNESS»(ref-496020-S00164477962012082100000) and «Maintenance, Diagnosis»(ref-496015-S28841274602012082100000) Removing and installing, refer to «BRAKE PADS, FS III»(ref-496082-S01768761862012082100000) Observe installed position «BRAKES, FS III ASSEMBLY OVERVIEW»(ref-496082-S38236545002012082100000) Must always be replaced together on both sides of axle
  5. Electrical Connection Remove from bracket -13- when replacing brake pad
  6. Brake Caliper Piston diameter, refer to «BRAKES»(ref-496091-S32532055972012082100000) Removing and installing, refer to «BRAKE CALIPER, FS III»(ref-496082-S22979349112012082100000) Servicing, refer to «BRAKE CALIPER, FS III ASSEMBLY OVERVIEW»(ref-496088-S00259311462012082100000) Brake caliper with a balance weight, refer to «BRAKE CALIPER WITH BALANCE WEIGHT»(ref-496082-S33569936702012082100000)
  7. Guide Pins 28 Nm
  8. Cap
  9. Brake Hose with Banjo Fitting and Union Bolt 35 Nm Anti-rotation device «BRAKES, FS III ASSEMBLY OVERVIEW»(ref-496082-S38236545002012082100000)
  10. Guide Pins 30 Nm
  11. Cap
  12. Sheet-Metal Screw
  13. Bracket
  14. Wheel Bearing Housing
  15. Wheel Speed Sensor Removing and installing, refer to «SPEED SENSOR AT FRONT AXLE»(ref-496083-S10100919372012082100000) Before inserting sensor, clean inner surface of bore and coat with hot bolt paste G 052 112 A3
  16. Hex Socket Head Bolt Tightening specification -4- «ANTI-LOCK BRAKE/ELECTRONIC STABILIZATION PROGRAM SYSTEM AT FRONT AXLE ASSEMBLY OVERVIEW»(ref-496083-S41880880952012082100000)
  17. Wheel Bearing Unit with Integrated Rotor Removing and installing, refer to «Removal and Installation»(ref-496073-S25116010052012082100000)
  18. Cover Plate
  19. Brake Pads With wear indicator (only on the left side) When the wear limit is reached, an indicator in the instrument cluster lights up. Pad thickness, wear limit, refer to «BRAKES»(ref-496091-S32532055972012082100000) Checking brake pad thickness, refer to «BRAKE PADS, CHECKING THICKNESS»(ref-496020-S00164477962012082100000) and «Maintenance, Diagnosis»(ref-496015-S28841274602012082100000) Removing and installing, refer to «BRAKE PADS, FS III»(ref-496082-S01768761862012082100000) Observe installed position «BRAKES, FS III ASSEMBLY OVERVIEW»(ref-496082-S38236545002012082100000) Must always be replaced together on both sides of axle

Scheme 2

Scheme 2: Installed Position of Brake Pads
Scheme 2: Installed Position of Brake Pads
  1. Pad with large three-finger clip -1- is for the piston side.
  2. Pad with small three-finger clip -2- (colored black) is for the outer side of the brake caliper.

Scheme 3

Scheme 3: Brake Hose Connection with Anti-Rotation Device
Scheme 3: Brake Hose Connection with Anti-Rotation Device

Make sure that the groove in the banjo fitting of the brake hose is inserted onto the locating tab -arrow-.

BRAKES, FN 3 ASSEMBLY OVERVIEW

Note. Install complete repair kit After replacing brake pads, depress brake pedal several times firmly to properly seat brake pads in their normal operating position. When siphoning brake fluid, always use a bleeder bottle that is used exclusively for brake fluid. Brake fluid is poisonous. NEVER siphon brake fluid with your mouth!

General notes BRAKES, FS III ASSEMBLY OVERVIEW

Scheme 4

Scheme 4: BRAKES, FN 3 ASSEMBLY OVERVIEW
Scheme 4: BRAKES, FN 3 ASSEMBLY OVERVIEW
  1. Bolt 10 Nm
  2. Brake Disc Allocation, dimensions, wear limits, refer to «BRAKES»(ref-496091-S32532055972012082100000) Remove brake caliper housing, to remove Do not use excessive force to separate the brake rotor from the wheel hub. If necessary, use rust penetrant, otherwise the brake rotors could be damaged. Must always be replaced together on both sides of axle
  3. Bolt 4 Nm
  4. Brake Pads Pad thickness, wear limit, refer to «BRAKES»(ref-496091-S32532055972012082100000) Checking brake pad thickness. refer to «BRAKE PADS, CHECKING THICKNESS»(ref-496020-S00164477962012082100000) and «Maintenance, Diagnosis»(ref-496015-S28841274602012082100000) Removing and installing, refer to «BRAKE PADS, FN 3»(ref-496082-S05628465422012082100000) Observe installed position «BRAKES, FN 3 ASSEMBLY OVERVIEW»(ref-496082-S12466889762012082100000) Must always be replaced together on both sides of axle
  5. Retaining Spring Insert in both holes of brake caliper housing
  6. Brake Carrier Supplied as replacement part assembled with sufficient grease on guide pins If the protective caps are damaged, install repair kit; use included grease packet to grease the guide pins
  7. Brake Caliper Housing Piston diameter, refer to «BRAKES»(ref-496091-S32532055972012082100000) different versions, To replace brake pads, unfasten from brake carrier Removing and installing, refer to «BRAKE CALIPER, FN 3»(ref-496082-S15756757902012082100000) Servicing, refer to «BRAKE CALIPER, FN3 ASSEMBLY OVERVIEW»(ref-496088-S11233444222012082100000) Brake caliper with a balance weight, refer to «BRAKE CALIPER WITH BALANCE WEIGHT»(ref-496082-S33569936702012082100000)
  8. Guide Pins 30 Nm
  9. Cap
  10. Brake Hose with Banjo Fitting and Union Bolt 35 Nm Anti-rotation device «BRAKES, FN 3 ASSEMBLY OVERVIEW»(ref-496082-S12466889762012082100000)
  11. Guide Pins 30 Nm
  12. Cap
  13. Sheet-Metal Screw
  14. Bracket
  15. Ribbed Bolt 190 Nm If using again, clean the ribs
  16. Wheel Bearing Housing
  17. Wheel Speed Sensor Removing and installing, refer to «SPEED SENSOR AT FRONT AXLE»(ref-496083-S10100919372012082100000) Before inserting sensor, clean inner surface of bore and coat with hot bolt paste G 052 112 A3
  18. Hex Socket Head Bolt Tightening specification, -item 4- in «ANTI-LOCK BRAKE/ELECTRONIC STABILIZATION PROGRAM SYSTEM AT FRONT AXLE ASSEMBLY OVERVIEW»(ref-496083-S41880880952012082100000)
  19. Wheel Bearing Unit with Integrated Rotor Removing and installing, refer to «Removal and Installation»(ref-496073-S25116010052012082100000)
  20. Cover Plate
  21. Brake Pads With wear indicator (only on the left side) When the wear limit is reached, an indicator in the instrument cluster lights up. Pad thickness, wear limit, refer to «BRAKES»(ref-496091-S32532055972012082100000) Checking brake pad thickness, refer to «BRAKE PADS, CHECKING THICKNESS»(ref-496020-S00164477962012082100000) and «Maintenance, Diagnosis»(ref-496015-S28841274602012082100000) Removing and installing, refer to «BRAKE PADS, FN 3»(ref-496082-S05628465422012082100000) Observe installed position «BRAKES, FN 3 ASSEMBLY OVERVIEW»(ref-496082-S12466889762012082100000) Must always be replaced together on both sides of axle
  22. Electrical Connection Remove from bracket -14- when replacing brake pad

Scheme 5

Scheme 5: Installed Position of Brake Pads
Scheme 5: Installed Position of Brake Pads

1 - right brake pad, piston side

2 - left brake pad, piston side

Note. In installed position, the arrow on the backing plate of the brake pad must point downward

BRAKES, FNRG60 ASSEMBLY OVERVIEW

Note. Install complete repair kit. After replacing brake pads, depress brake pedal several times firmly to properly seat brake pads in their normal operating position. When siphoning brake fluid, always use a bleeder bottle that is used exclusively for brake fluid. Brake fluid is poisonous. NEVER siphon brake fluid with your mouth! Check brake caliper for ease of movement by moving it sideways.

Scheme 6

Scheme 6: BRAKES, FNRG60 ASSEMBLY OVERVIEW
Scheme 6: BRAKES, FNRG60 ASSEMBLY OVERVIEW
  1. Brake Pads NOTE: The inner surface (with tension spring) is equipped with a cable for wear indicator. Must always be replaced together on both sides of axle Before installing the brake pads, clean the pad guide surface and coat it with a film of polycarbamide grease G 052 142 A2. Removing and installing Checking brake pad thickness, refer to «BRAKE PADS, CHECKING THICKNESS»(ref-496020-S00164477962012082100000) and «Maintenance, Diagnosis»(ref-496015-S28841274602012082100000) NOTE: Before installing new brake pads, thoroughly clean the brake calipers of contaminants (grease-free). When doing this, pay particular attention to the cleanliness of the brake pad contact surfaces.
  2. Brake Carrier Bolt to wheel bearing housing
  3. Ribbed Bolt 196 Nm M14 X 1.5x 38 If using again, clean the ribs
  4. Bushing Insert in brake caliper housing
  5. Guide Pins 30 Nm
  6. Cap Remove Hook in the cable for wear indicator
  7. Brake Disc Must always be replaced together on both sides of axle Remove brake caliper before removing Coat contact surfaces between brake disc and wheel hub with Polycarbamide grease G 052 142 A2. Allocation, dimensions, wear limits, refer to «BRAKES»(ref-496091-S32532055972012082100000) Checking thickness, refer to «BRAKE PADS, CHECKING THICKNESS»(ref-496020-S00164477962012082100000) and «Maintenance, Diagnosis»(ref-496015-S28841274602012082100000)
  8. Wheel Bolts Mounting wheels, refer to «WHEEL, CHANGING AND MOUNTING»(ref-496016-S24695209962012082100000)
  9. Bolt Tightening specification, 5 Nm
  10. Spring Clamp
  11. Brake Line Connector to Brake Hose, 12 Nm
  12. Brake Line Install in the brake caliper housing Screwed together with brake hose, held against the hex nut of the brake hose. Hose must be installed free of twists Make sure that lugs are properly seated in grooves in bracket.
  13. Brake Line Connection to Brake Caliper 19 Nm
  14. Bracket Bolt to brake caliper housing Hook in brake line
  15. Bolt M 8x 16 Tightening specification, 25 Nm
  16. Brake Caliper Housing When doing work, do not allow to hang from brake hose, rather suspend it from the body using bundling wire Except for replacing brake pads and servicing front brake caliper, no other repairs should be performed on the brake caliper Hose must be installed free of twists Brake caliper with a balance weight, refer to «BRAKE CALIPER WITH BALANCE WEIGHT»(ref-496082-S33569936702012082100000)
  17. Retaining Spring Observe correct installed position. NOTE: After hooking into both studs, the retaining spring must be pressed under the brake carrier. If improperly installed, the wear of the outer brake pad cannot be adjusted, thereby increasing brake pedal travel.

BRAKES WITH FRONT WHEEL DRIVE ASSEMBLY OVERVIEW

Note. To siphon off brake fluid from the brake fluid reservoir, use the brake charger/bleeder unit VAS 5234 or the brake charger/bleeder unit adapter V.A.G 1869/4. Before removing a brake caliper or disconnecting a brake hose from a brake caliper, install the brake pedal actuator V.A.G 1869/2, to prevent the brake fluid reservoir from draining.

CAUTIONAfter installing brake pads, depress brake pedal several times firmly to properly seat brake pads in their normal operating position.

Scheme 7

Scheme 7
Scheme 7
  1. Wheel Speed Sensor Removing and installing, refer to «SPEED SENSOR AT REAR AXLE WITH FRONT-WHEEL DRIVE»(ref-496083-S00313755012012082100000) Before inserting sensor, clean inner surface of bore and coat with hot bolt paste G 052 112 A3
  2. Hex Socket Head Bolt 8 Nm
  3. Hex Socket Head Bolt Always replace 90 Nm plus an additional 90° turn
  4. Wheel Bearing Housing Removing and installing, refer to «Removal and Installation»(ref-496074-S34198699592012082100000)
  5. Cover Plate
  6. Hex Bolt 10 Nm
  7. Wheel Bearing/Hub Unit
  8. 8 - Brake Disc Allocation, dimensions, wear limits, refer to «BRAKES»(ref-496091-S32532055972012082100000) Do not use excessive force to separate the brake rotor from the wheel hub. If necessary, use rust penetrant, otherwise the brake rotors could be damaged. Remove brake caliper prior to removing Must always be replaced together on both sides of axle
  9. Bolt 4 Nm
  10. Twelve-Point Nut Tightening specification, refer to «Description and Operation»(ref-496074-S31950126472012082100000)
  11. Brake Pads Pad thickness, wear limit, refer to «BRAKES»(ref-496091-S32532055972012082100000) Checking brake pad thickness, refer to «BRAKE PADS, CHECKING THICKNESS»(ref-496020-S00164477962012082100000) and «Maintenance, Diagnosis»(ref-496015-S28841274602012082100000) Removing and installing, refer to «BRAKE PADS»(ref-496082-S10517957692012082100000) Must always be replaced together on both sides of axle
  12. Brake Carrier With guide pins and protective cap Supplied as an assembled replacement part with sufficient grease on guide pins If the protective caps are damaged, install repair kit; use included grease packet to grease the guide pins
  13. Brake Pad Securing Spring Always replace when pads are replaced
  14. Brake Caliper Housing Do not disconnect brake hose when changing brake pads Piston diameter «BRAKES»(ref-496091-S32532055972012082100000) Removing and installing, refer to «BRAKE CALIPER»(ref-496082-S41133296962012082100000) Servicing, refer to «REAR BRAKE CALIPER ASSEMBLY OVERVIEW»(ref-496088-S26931619032012082100000) After service work or replacement, the brake cable must be adjusted first, refer to «PARKING BRAKE, ADJUSTING»(ref-496082-S39870475962012082100000)
  15. Hose Retainer
  16. Brake Line 14 Nm
  17. Bolt 35 Nm Self-locking When loosening and tightening, counter-hold at guide pin Always replace after removal
  18. Parking Brake Cable Removing and installing, refer to «PARKING BRAKE CABLE»(ref-496082-S26612861462012082100000) Adjusting the parking brake, refer to «PARKING BRAKE, ADJUSTING»(ref-496082-S39870475962012082100000)
  19. Spring Clamp
  20. Brake Hose with Spacer Bracket
  21. Spacer Install spacer bracket on brake caliper side

BRAKES WITH ALL WHEEL DRIVE ASSEMBLY OVERVIEW

General notes BRAKES WITH FRONT WHEEL DRIVE ASSEMBLY OVERVIEW

Scheme 8

Scheme 8: BRAKES WITH ALL WHEEL DRIVE ASSEMBLY OVERVIEW
Scheme 8: BRAKES WITH ALL WHEEL DRIVE ASSEMBLY OVERVIEW
  1. Hex Socket Head Bolt Always replace 90 Nm plus an additional 90° turn
  2. Wheel Bearing Housing Removing and installing, refer to «Removal and Installation»(ref-496074-S34198699592012082100000)
  3. Wheel Speed Sensor Removing and installing, refer to «SPEED SENSOR AT REAR AXLE WITH FRONT-WHEEL DRIVE»(ref-496083-S00313755012012082100000) Before inserting sensor, clean inner surface of bore and coat with hot bolt paste G 052 112 A3
  4. Hex Socket Head Bolt 8 Nm
  5. Cover Plate
  6. Hex Bolt 10 Nm
  7. Wheel Bearing/Hub Unit
  8. Bolt 4 Nm
  9. Brake Disc Allocation, dimensions, wear limits, refer to «BRAKES»(ref-496091-S32532055972012082100000) Do not use excessive force to separate the brake rotor from the wheel hub. If necessary, use rust penetrant, otherwise the brake rotors could be damaged. Remove brake caliper prior to removing Must always be replaced together on both sides of axle
  10. Brake Pads Pad thickness, wear limit, refer to «BRAKES»(ref-496091-S32532055972012082100000) Checking brake pad thickness, refer to «BRAKE PADS, CHECKING THICKNESS»(ref-496020-S00164477962012082100000) and «Maintenance, Diagnosis»(ref-496015-S28841274602012082100000) Removing and installing, refer to «BRAKE PADS»(ref-496082-S10517957692012082100000) Must always be replaced together on both sides of axle
  11. Brake Carrier With guide pins and protective cap Supplied as an assembled replacement part with sufficient grease on guide pins If the protective caps are damaged, install repair kit; use included grease packet to grease the guide pins
  12. Brake Pad Securing Spring Always replace when pads are replaced
  13. Brake Caliper Housing Do not disconnect brake hose when changing brake pads Piston diameter «BRAKES»(ref-496091-S32532055972012082100000) Removing and installing, refer to «BRAKE CALIPER»(ref-496082-S41133296962012082100000) Servicing, refer to «REAR BRAKE CALIPER ASSEMBLY OVERVIEW»(ref-496088-S26931619032012082100000) After service work or replacement, the brake cable must be adjusted first, refer to «PARKING BRAKE, ADJUSTING»(ref-496082-S39870475962012082100000)
  14. Hose Retainer
  15. Brake Line 14 Nm
  16. Bolt 35 Nm Self-locking When loosening and tightening, counter-hold at guide pin Always replace after removal
  17. Parking Brake Cable Removing and installing, refer to «PARKING BRAKE CABLE»(ref-496082-S26612861462012082100000) Adjusting the parking brake, refer to «PARKING BRAKE, ADJUSTING»(ref-496082-S39870475962012082100000)
  18. Spring Clamp
  19. Brake Hose with Spacer Bracket
  20. Spacer Install spacer bracket on brake caliper side

BRAKE PEDAL ASSEMBLY OVERVIEW, MANUAL TRANSMISSION

Note. If the vehicle has a brake lamp switch depends on the model.

WARNINGThe path of the brake pedal must not be shortened via extra floor mats.

Scheme 9

Scheme 9
Scheme 9
  1. Mounting Bracket
  2. Nut 25 Nm
  3. Brake Pedal Switch -F47- NOTE: If the vehicle has a brake lamp switch depends on the model. Before installing the brake lamp switch, the brake pedal must be clipped together with the brake booster push rod, refer to «BRAKE PEDAL AND BRAKE BOOSTER»(ref-496082-S37655335722012082100000) Removing and installing, adjusting, refer to «BRAKE LAMP SWITCH ON BRAKE PEDAL»(ref-496083-S41937800342012082100000) Coat plunger head with polyurea grease G 052 142 A2.
  4. Hex Head Bolt
  5. Brake Pedal Removing and installing, refer to «BRAKE PEDAL»(ref-496082-S16614315402012082100000) Disconnect from brake booster, refer to «BRAKE PEDAL AND BRAKE BOOSTER»(ref-496082-S37655335722012082100000) Lubricate mounting points with polyurea grease G 052 142 A2 before installing
  6. Cover
  7. Ball Socket
  8. Mount For ball head of brake servo push rod
  9. Nut 25 Nm
  10. Bushing Lubricate mounting points with polyurea grease G 052 142 A2 before installing
  11. Pivot Pin

BRAKE PEDAL ASSEMBLY OVERVIEW AUTOMATIC TRANSMISSION

Note. If the vehicle has a brake lamp switch depends on the model.

CAUTIONThe path of the brake pedal must not be shortened via extra floor mats.

Scheme 10

Scheme 10
Scheme 10
  1. Mounting Bracket
  2. Nut 25 Nm
  3. Brake Pedal Switch -F47- NOTE: If the vehicle has a brake lamp switch depends on the model. Before installing the brake lamp switch, the brake pedal must be clipped together with the brake booster push rod, refer to «BRAKE PEDAL AND BRAKE BOOSTER»(ref-496082-S37655335722012082100000) Removing and installing, adjusting, refer to «BRAKE LAMP SWITCH ON BRAKE PEDAL»(ref-496083-S41937800342012082100000) Lubricate plunger head with polycarbamide grease G 052 142 A2.
  4. Hex Head Bolt
  5. Brake Pedal Removing and installing, refer to «BRAKE PEDAL»(ref-496082-S16614315402012082100000) Disconnect from brake booster, refer to «BRAKE PEDAL AND BRAKE BOOSTER»(ref-496082-S37655335722012082100000) Lubricate mounting points with polyurea grease G 052 142 A2 before installing
  6. Cover
  7. Ball Socket
  8. Mount For ball head of brake servo push rod
  9. Nut 25 Nm
  10. Bushing Lubricate mounting points with polyurea grease G 052 142 A2 before installing
  11. Pivot Pin

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