Mechanical Components - Brake System (coupe) Audi A5 I

FRONT BRAKES, 1LT

Note. Install complete repair set. 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!

Overview

Scheme 1

1. Brake Shield
2. Bolt 18 Nm
3. Tension Spring Must fit inside the brake piston.
4. Harness Connector Remove from the bracket when replacing the brake pad.
5. Bolt 190 Nm
6. Brake Carrier Attach to wheel bearing housing.
7. Brake Pads Wear limit, refer to «BRAKES PR CODES»(/audi/a5/i-2007-2011/remont/anti-locktraction-control/#general-technical-data-brake-system-coupe__brakes-pr-codes) . Removing and Installing, refer to «BRAKE PADS»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe__brake-pads) . NOTE: The inner surface (with tension spring) is indicated by an arrow. The arrow must point in the direction of forward rotation of the brake rotor when installed. If improperly installed, noises could result. Before installing the brake pads, clean the pad guide surface and coat it with a film of Polycarbamide grease G 052 142 A2. NOTE: Remove any adhesive film on the back of the brake pad before installing. Left front brake pad wear indicator. With adequate wear, the warning light in the instrument cluster lights up. Must always be replaced together on both sides of axle. Removing and Installing, refer to «BRAKE PADS»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe__brake-pads) . Checking brake pad thickness. There are different versions . NOTE: Before installing new brake pads, thoroughly clean the brake calipers of contaminants (grease-free). When doing so, pay particular attention to removing any remaining adhesive foil on outer brake pad contact surfaces.
8. Spring Before installing the brake pads, clean the pad guide surface and coat it with a film of Polycarbamide grease G 052 142 A2. Insert in both holes of brake caliper housing. NOTE: Retaining spring must be pressed under brake carrier after it is inserted in both holes. If improperly installed, the wear of the outer brake pad cannot be adjusted, thereby increasing brake pedal travel.
9. Brake Rotor Wear limit, refer to «BRAKES PR CODES»(/audi/a5/i-2007-2011/remont/anti-locktraction-control/#general-technical-data-brake-system-coupe__brakes-pr-codes) . Must always be replaced together on both sides of axle. Remove brake caliper before removing. Removing and Installing, refer to «FRONT BRAKE ROTOR»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe__front-brake-rotor) .
10. Bolt 5 Nm
11. Brake Caliper Housing To replace brake pads, unfasten from brake carrier. Brake caliper, servicing, refer to «BRAKE CALIPER, SERVICING, 1LT»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#hydraulic-components-brake-system-coupe__brake-caliper-servicing-1lt) .
12. Guide Pins 30 Nm
13. Cap Remove the guide pins to remove. Insert the guide pins after installation.
14. Brake Hose Do not remove the brake hose when changing the brake pads. Install in the brake caliper housing. Brake caliper side 16 Nm.

FRONT BRAKES, 1LA/ 1LJ

Note. Install the entire 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.

Overview

Scheme 2

1. Brake Pads Wear limit, refer to «BRAKES PR CODES»(/audi/a5/i-2007-2011/remont/anti-locktraction-control/#general-technical-data-brake-system-coupe__brakes-pr-codes) . Illustration of left front with brake wear cable. NOTE: The inner surface (with tension spring) in the left brake caliper 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, refer to «FRONT BRAKE PADS»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe__front-brake-pads) . Checking brake pad thickness, refer to. There are different versions . 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 Attach to wheel bearing housing. The retaining pins for the brake pads on the brake carrier must not be loosened under any circumstances.
3. Bolt Brake carrier to wheel bearing housing. Use new bolts . 196 Nm
4. Bolt Tighten the brake caliper to the brake carrier. 30 Nm
5. Brake Line Connection to the Brake Caliper 20 Nm
6. Bolt CAUTION: The 4 bolts must not be loosened under any circumstances.
7. Brake Caliper Housing When doing work, do not allow to hang from brake hose, rather suspend it from the body using bundling wire. The brake caliper must not be disassembled. Except for "Brake Pads, Removing and Installing" «FRONT BRAKE PADS»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe__front-brake-pads) , "Front Brake Caliper, Servicing" and replacing the guide pins, no further repairs should made to the brake caliper. Hose must be installed free of twists.
8. Spring Clamp Remove the brake pads before removal. Insert after installing the brake pads.
9. Brake Pad Retaining Pins CAUTION: The 4 retaining pins for the brake pads on the brake carrier must not be loosened under any circumstances.
10. Securing the Brake Pad in the Brake Caliper
11. Brake Rotor Wear limit, refer to «BRAKES PR CODES»(/audi/a5/i-2007-2011/remont/anti-locktraction-control/#general-technical-data-brake-system-coupe__brakes-pr-codes) . Must always be replaced together on both sides of axle. Removing and Installing, refer to «FRONT BRAKE ROTOR»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe) . Coat contact surfaces between brake rotor and wheel hub with Polycarbamide grease G 052 142 A2. Refer to «General Information»(/audi/a5/i-2007-2011/remont/wheel-tire-system/#suspension-wheels-steering-coupe) «General Information»(/audi/a5/i-2007-2011/remont/wheel-tire-system/#wheel-and-tire-guide-coupe) . Allocation Thickness
12. Brake Pad Bolt 5 Nm

FRONT BRAKES, 1LM

Note. Always install complete repair set. After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the brake pads are properly seated 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!

Overview

Scheme 3

1. Bolt 5 Nm NOTE: Replace each time it is removed.
2. Brake Rotor Wear limit, refer to «BRAKES PR CODES»(/audi/a5/i-2007-2011/remont/anti-locktraction-control/#general-technical-data-brake-system-coupe__brakes-pr-codes) . Must always be replaced together on both sides of axle. Remove brake caliper before removing. Coat contact surfaces between brake rotor and wheel hub with Polycarbamide grease . Removing and Installing, refer to «FRONT BRAKE ROTOR»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe) . Replacing, refer to «FRONT BRAKE ROTOR, REPLACING»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe) .
3. Cover Plate Bolt 10 Nm
4. Cover Plate Removing and Installing, refer to «FRONT BRAKE ROTOR»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe) .
5. Stub Axle Carrier NOTE: Attach the brake hose bracket and brake pad wear wire to the stub axle carrier. Bolt for the bracket 9 Nm.
6. Wheel Speed Sensor Removing and installing
7. Bolt 9 Nm
8. Brake Hose NOTE: Brake hose in brake caliper 16 Nm. Brake pressure line to brake hose: 16 Nm.
9. Brake Piston
10. Guide Pins
11. Brake Pad Spring 2 installed in each brake caliper. Ensure installation position is correct.
12. Brake Caliper Bolt 196 Nm NOTE: Replace each time it is removed.
13. Brake Caliper When working on the brake caliper, do not let it hang by the brake hose, but secure it to the body with suitable cable ties or wire. Except for "Brake Pads, Removing and Installing " and "Front Brake Caliper, Servicing", no further repairs should made to the brake caliper. Hose must be installed free of twists. Brake allocation. NOTE: Bleed the brake caliper at both bleed screws. No repairs may be performed on the brake caliper. Brake Caliper, Removing and Installing, refer to «FRONT BRAKE CALIPER»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe__front-brake-caliper) . Brake Caliper, Removing and Installing, refer to «FRONT BRAKE CALIPER, REPLACING»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe) .
14. Brake Pads Installed 4 times in each front brake caliper. Wear limit, refer to «BRAKES PR CODES»(/audi/a5/i-2007-2011/remont/anti-locktraction-control/#general-technical-data-brake-system-coupe__brakes-pr-codes) . WARNING: There are four brake pads installed per side. Only the inner top brake pad in the left brake caliper has a connection for the brake pad wear indicator. The brake pad backing plates are equipped with an adhesive film. Remove the protective film from the adhesive surface before inserting. Must always be replaced together on both sides of axle. Removing and Installing, refer to «BRAKE PADS»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe) . Checking brake pad thickness. NOTE: Before installing new brake pads, thoroughly clean the brake calipers of contaminants (grease-free). When doing so, pay particular attention to removing any remaining adhesive foil on outer brake pad contact surfaces.

FRONT BRAKES, 1LW

Note. Check the ceramic brake rotors for damage and wear each time the brake pads are changed.

1. Ceramic Brake Rotor, Checking for Damage, refer to «CERAMIC BRAKE ROTORS, EVALUATING»(/audi/a5/i-2007-2011/remont/anti-locktraction-control/#general-technical-data-brake-system-coupe__ceramic-brake-rotors-evaluating) .
2. Ceramic Brake Rotor, Checking for Wear, refer to «CERAMIC BRAKE ROTORS, DETERMINING WEAR»(/audi/a5/i-2007-2011/remont/anti-locktraction-control/#general-technical-data-brake-system-coupe__ceramic-brake-rotors-determining-wear) .

Note. Always install complete repair set. After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the brake pads are properly seated 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!

Overview

Scheme 4

1. Brake Caliper Bolts NOTE: It is not necessary to loosen these bolts to remove the brake caliper. Only the bolts -10- are loosened and removed.
2. Brake Pad Retaining Spring Make sure it is installed in the correct position.
3. Guide Pins Push them from the outside toward the inside through the brake caliper and the brake pads. NOTE: Make sure then fits correctly inside the brake caliper. The groove on the guide pin must fit inside the groove inside the brake caliper.
4. Brake Caliper When doing work, do not allow to hang from brake hose, rather suspend it from the body using bundling wire. Except for "Brake Pads, Removing and Installing " and "Front Brake Caliper, Servicing", no further repairs should made to the brake caliper. Install hose so it is not twisted. Brake allocation, refer to «BRAKES PR CODES»(/audi/a5/i-2007-2011/remont/anti-locktraction-control/#general-technical-data-brake-system-coupe__brakes-pr-codes) . Removing and Installing, refer to «BRAKE CALIPER»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe__brake-caliper) . Replacing, refer to «BRAKE CALIPER, REPLACING»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe) .
5. Brake Pads Wear limit NOTE: The inner pad is equipped with a cable for the wear indicator. The brake pads may have a protective film on the back of the pad. Peel off the protective foil before installing. Before installing the brake pads, clean the pad guide surface and coat it with a film of Polycarbamide grease . Must always be replaced together on both sides of axle. Removing and Installing, refer to «BRAKE PADS»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe) . Checking brake pad thickness.
6. Bolt 5 Nm. NOTE: Replace each time it is removed.
7. Brake Rotor Wear, Determining, refer to «CERAMIC BRAKE ROTORS, DETERMINING WEAR»(/audi/a5/i-2007-2011/remont/anti-locktraction-control/#general-technical-data-brake-system-coupe__ceramic-brake-rotors-determining-wear) . Must always be replaced together on both sides of axle. Remove brake caliper before removing. Coat the contact surfaces between the brake rotor and the wheel hub with polycarbamide grease G 052 142 A2. Brake rotor allocation. Removing and Installing, refer to «CERAMIC BRAKE ROTOR»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe) . Replacing, refer to «CERAMIC BRAKE ROTOR, REPLACING»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe__ceramic-brake-rotor-replacing) .
8. Cover Plate Removing and Installing, refer to «FRONT BRAKE SHIELD»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe) .
9. Cover Plate Bolts 9 Nm.
10. Bolts NOTE: Loosen these bolts to remove the brake caliper. Always replace if removed. 190 Nm.
11. Brake Carrier Attach to wheel bearing housing. Bolted to the brake caliper. 196 Nm. NOTE: The brake carrier is not a replacement part.
12. Brake Piston WARNING: The brake pistons have different diameters. When re-installing, ensure the respective brake piston is inserted in the correct bore in the brake caliper. The ceramic inserts on the brake pistons serve as heat insulators and must not be removed from the pistons. If the ceramic inserts are damaged, the brake pistons must be replaced for safety reasons.
13. Bracket Bolt 25 Nm
14. Brake Line Connection to Brake Line Brake hose must not be twisted. 14 Nm.
15. Brake Line Install in the brake caliper housing. Counterhold by the hexagon on the brake hose and attach to the brake hose. Hose must be installed free of twists. Make sure that lugs are properly seated in grooves in bracket.
16. Bracket for Brake Line Bolt to brake caliper housing. Hook in brake line.
17. Brake Line in Brake Caliper 16 Nm
18. Guide Pins Bolt 30 Nm
19. Balance Spring Each brake caliper has two. Disengaging and engaging, refer to «BALANCE SPRING, DISENGAGING AND ENGAGING»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe) .

REAR BRAKES WITH ELECTRONIC PARKING BRAKE OVERVIEW

Note. Only install complete repair kit. Rear wheel brake with automatic adjustment.

Scheme 5

1. Self-Locking Bolt 12 Nm
2. Electromechanical Parking Brake Actuator Electromechanical parking brake control module, removing and installing, refer to «Electromechanical Parking Brake Control Module -J540»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe__electromechanical-parking-brake-control-module-j540) . Actuator, removing and installing, refer to «ELECTROMECHANICAL PARKING BRAKE ACTUATOR»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe__electromechanical-parking-brake-actuator) .
3. Seal Always replace.
4. Self-Locking Bolt 35 Nm Always replace. When loosening and tightening, counter-hold at guide pin.
5. Spacer
6. Brake Hose To the brake caliper, 20 Nm. Do not disconnect brake line when changing brake pads. Make sure that retaining tabs are seated correctly in bracket. Install hose without twisting.
7. Brake Caliper Housing Do not remove the brake hose when changing the brake pads. Brake caliper, servicing. It is possible to install brake carrier with brake caliper. Removing and Installing, refer to «REAR BRAKE CALIPER WITH BRAKE CARRIER»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe) . Replacing, refer to «REAR BRAKE CALIPER, REPLACING»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe__rear-brake-caliper-replacing) .
8. Brake Carrier with Guide Pins and Cap Supplied as an assembled replacement part with sufficient grease on guide pins. If protective caps or guide pins are damaged, install repair kit. Use grease packet supplied to lubricate guide pins. It is possible to install brake carrier with brake caliper. Removing and Installing, refer to «REAR BRAKE CALIPER WITH BRAKE CARRIER»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe) .
9. Brake Pads Wear limit, refer to «BRAKES PR CODES»(/audi/a5/i-2007-2011/remont/anti-locktraction-control/#general-technical-data-brake-system-coupe__brakes-pr-codes) . Must always be replaced together on both sides of axle. Removing and Installing, refer to «REAR BRAKE PADS»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe__rear-brake-pads) . Checking brake pad thickness It is possible to install brake carrier with brake caliper. NOTE: The brake pads must be seated between both securing tabs on the pad retaining plate to provide the air gap between the brake rotor and brake pad.
10. Brake Pad Retaining Plate Always replace when pads are replaced. NOTE: The brake pads must be seated between both securing tabs on the pad retaining plate to provide the air gap between the brake rotor and brake pad.
11. Wheel Bolts Wheels, Mounting, refer to «Special Tools»(/audi/a5/i-2007-2011/remont/wheel-tire-system/#suspension-wheels-steering-coupe__special-tools) .
12. Bolt 5 Nm
13. Brake Rotor Wear limit, refer to «BRAKES PR CODES»(/audi/a5/i-2007-2011/remont/anti-locktraction-control/#general-technical-data-brake-system-coupe__brakes-pr-codes) . Removing and Installing, refer to «REAR BRAKE ROTOR»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe) . Must always be replaced together on both sides of axle. Brake rotor allocation, refer to «BRAKES PR CODES»(/audi/a5/i-2007-2011/remont/anti-locktraction-control/#general-technical-data-brake-system-coupe__brakes-pr-codes) .
14. Hex Head Bolts 10 Nm
15. Brake Shield Removing and Installing, refer to «REAR BRAKE SHIELD»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe) .
16. Bolt 100 Nm + 90° turn Replace
17. Bolts 100 Nm + 90° turn Replace

BRAKE PEDAL AND MOUNTING BRACKET OVERVIEW

1. Lubricate all bearing and contact surfaces with lubricant part no. Lubricant G 000 450 02.

Scheme 6

1. Mounting Bracket for Pedal Assembly Illustration for vehicles with automatic transmission. Removing and Installing, Manual Transmission, refer to «MOUNTING BRACKET, MANUAL TRANSMISSION»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe__mounting-bracket-manual-transmission) . Removing and Installing, Automatic Transmission, refer to «MOUNTING BRACKET, AUTOMATIC TRANSMISSION»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe__mounting-bracket-automatic-transmission) .
2. Sleeve
3. Brake Pedal Axle
4. Bearing Pin
5. Right Securing Clip (Spring Steel)
6. Washer
7. Gas Pedal Module Bolt 8 Nm
8. Accelerator Pedal Module
9. Pedal Support Bolt 20 Nm
10. Brake Lamp Sensor Removing and Installing, refer to «BRAKE LAMP SENSOR»(/audi/a5/i-2007-2011/remont/anti-locktraction-control/#anti-lock-brake-system-coupe__brake-lamp-sensor) .
11. Mounting Pin Bolt The bolt holds the mounting pins in position. 8 Nm
12. Left Securing Clip (Spring Steel)
13. Brake Pedal Removing and Installing, Manual Transmission, refer to «BRAKE PEDAL, MANUAL TRANSMISSION»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe) . Removing and Installing, Automatic Transmission, refer to «BRAKE PEDAL, AUTOMATIC TRANSMISSION»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe__brake-pedal-automatic-transmission) . WARNING: If possible, leave the brake pedal stop installed; it could break the mount for the brake lamp sensor if the brake pedal is released too quickly.
14. Ball Socket Formed in Mount For the ball head on the brake booster push rod.
15. Mount For the ball head on the brake booster push rod. With ball stud retaining tabs. Removing and Installing, refer to «BRAKE BOOSTER PLUNGER MOUNT»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe__brake-booster-plunger-mount) .
16. Nut 8 Nm
17. Stop WARNING: If possible, leave the brake pedal stop installed; it could break the mount for the brake lamp sensor if the brake pedal is released too quickly.
18. Grommet Installed only vehicles with an automatic transmission.

Scheme 7

1. Parking Brake Contact Switch -F321- The switch is always illuminated so it can be found in the dark. Pull the --> close button. Press the --> open button. It is necessary to press the foot brake. Component location: in center console. Removing and installing, refer to «Parking Brake Switch -F321»(/audi/a5/i-2007-2011/remont/anti-locktraction-control/#anti-lock-brake-system-coupe) .
2. LED (Light Emitting Diode) Component location: In the parking brake switch. Lights up when the parking brake is engaged. Also indicated by the function light in the instrument cluster. NOTE: The bars in the switch turn red during dynamic deceleration greater than 7 km/h. A audible warning signal also sounds.
3. EPB System Malfunction Indicator (Yellow) If the parking brake malfunctions, a yellow symbol and the indicator Parking brake! appears in the instrument cluster display.
4. Electromechanical Parking Brake Function Lamps The Lamp is Red Clamping force display. Indicator light comes on when parking brake is closed and ignition is on. After switching off ignition, indicator light stays on for about 20 seconds. If the parking brake is closed with ignition off, the indicator light comes on for about 20 seconds. The indicator light must go out when the parking brake is released. The Lamp Blinks Red If the indicator lamp blinks red continuously after engaging the parking brake, it may be due to the following: The braking force from the parking brake is not sufficient to prevent the vehicle from rolling. The brake temperature is too high. If the indicator lamp is blinking red, another method must be used to prevent the vehicle from rolling. The Lamp is Green Function light with Audi Hold Assist activated. Additional Yellow Lamp If the parking brake malfunctions, a yellow symbol and the indicator Parking brake! appears in the instrument cluster display.
5. Electrical Parking Brake Actuator with Brake Caliper Removing and Installing, refer to «ELECTROMECHANICAL PARKING BRAKE ACTUATOR»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe__electromechanical-parking-brake-actuator) . Brake Caliper, Removing and Installing, refer to «REAR BRAKE CALIPER WITH BRAKE CARRIER»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe) .
6. Electromechanical Parking Brake Control Module -J540- Component location: in the right rear side panel behind the side trim. Removing and Installing, refer to «Electromechanical Parking Brake Control Module -J540»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe__electromechanical-parking-brake-control-module-j540) . 9 Nm
7. Electrical Parking Brake Actuator with Brake Caliper Removing and Installing, refer to «REAR BRAKE CALIPER PISTON»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#hydraulic-components-brake-system-coupe__rear-brake-caliper-piston) . Brake Caliper, Removing and Installing, refer to «REAR BRAKE CALIPER WITH BRAKE CARRIER»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#mechanical-components-brake-system-coupe) .
8. Acoustic Signal Warning if it is operated while driving greater than 7 km/h. Warning when a malfunction is detected in the system.

FASTENER TIGHTENING SPECIFICATIONS

BRAKE PADS

Note. Always replace on both axles.

Special tools and workshop equipment required

1. Torque Wrench 5-50 Nm V.A.G 1331
2. Reversible Ratchet V.A.G. 1331/1
3. Piston Resetting Tool T10145

REMOVING

Raise the vehicle.

Remove the wheels.

Note. When removing, mark brake pads that will be used again. Install in the same position, otherwise braking effect will be uneven!

Remove the caps -13-.

For vehicles with the brake wear pad indicator, disconnect the left front connector -4-.

Lift securing strap slightly at bottom of connector and then rotate 90°.

Remove the lower part of the brake pad wear indicator connector from the bracket.

Using screwdriver, pry off brake pad retaining spring from brake caliper housing and remove.

Scheme 8

Loosen and remove both guide pins -12- from the brake caliper.

Scheme 9

Note. Secure the brake caliper to the vehicle with a suitable wire. Do not support the weight with the brake hose.

Remove brake pads from brake caliper housing or from brake carrier.

INSTALLING

Clean the brake caliper housing.

Note. Clean brake caliper with mineral spirits exclusively. Before inserting new brake pads, press the piston back into the cylinder using the piston resetting tool. Before pushing back the piston, siphon some of the brake fluid out of the brake fluid reservoir. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage.

Press piston back.

Use the T10145.

Scheme 10

Insert brake pad with retaining spring into brake caliper housing (piston).

Scheme 11

Note. The inner surface (with tension spring) is indicated by an arrow. The arrow must point in the direction of forward rotation of the brake rotor when installed. If improperly installed, noises could result.

Remove any protective film from the brake pad backing plate.

Install outer brake pad on brake carrier.

Install both guide pins in the brake caliper housing and tighten.

Install both caps -arrow-.

Scheme 12

Install retaining spring in brake caliper housing.

Note. Retaining spring must be pressed under brake carrier after it is inserted in both holes. If improperly installed, the wear of the outer brake pad cannot be adjusted, thereby increasing brake pedal travel. After installing brake pads, depress brake pedal several times firmly to properly seat brake pads in their normal operating position.

Check brake fluid level, and fill if necessary.

Note. Make sure the brakes are working correctly before driving the vehicle for the first time.

FRONT BRAKE CALIPER WITH BRAKE CARRIER

Note. Always use new bolts.

Special tools and workshop equipment required

1. Torque Wrench 40-200 Nm V.A.G 1332
2. Reversible Ratchet V.A.G. 1332/1

Raise the vehicle.

Remove the wheels.

Remove the brake hose from the bracket.

Disconnect the brake wear indicator on the left brake caliper.

Remove the bolts -5- from the brake carrier.

Remove the brake carrier with brake pads and the brake caliper.

Note. Do not let the brake caliper with the brake carrier hang from the brake hose. Secure it to the body with suitable cable ties or wire. Do not support the weight with the brake hose.

Note. Always use new bolts .

Carefully press the brake caliper with the brake carrier and the brake pads installed over the brake rotor.

Tighten the brake carrier with new bolts -5-.

Place the brake hose in the bracket.

Mount the wheels.

Wheel bolt tightening specification, refer to Special Tools .

Lower the vehicle.

FRONT BRAKE CALIPER, REPLACING

Note. Always use new bolts .

Special tools and workshop equipment required

1. Torque Wrench 40-200 Nm V.A.G 1332
2. Reversible Ratchet V.A.G. 1332/1
3. Torque Wrench 5-50 Nm V.A.G 1331
4. Reversible Ratchet V.A.G. 1331/1
5. Brake Pedal Actuator V.A.G 1869/2
6. Piston Resetting Tool T10145

Insert the V.A.G 1869/2 between the brake pedal and driver seat by pressing the brake pedal down at least 60 mm.

Scheme 13

Raise the vehicle.

Remove the wheels.

Connect the hose from a bleeder bottle to one of the bleeder screws on the front caliper.

Open a bleeder screw on the front brake caliper to reduce the pressure from the brake system.

Close the bleeder screw.

Note. Do not remove brake pedal loading device V.A.G 1869/2.

Remove brake pads, refer to BRAKE PADS .

Note. When removing, mark brake pads that will be used again. Install in the same position, otherwise braking effect will be uneven! A bolt secure the brake rotor.

Remove brake hose from brake caliper.

Remove the brake caliper from the vehicle.

Remove the bolts -5- on the brake carrier while holding the carrier securely.

Remove the brake carrier.

Note. Always use new bolts .

Position the brake carrier.

Tighten the brake carrier with new bolts -5-.

Install the brake hose into the brake caliper and tighten.

Install brake pads, refer to BRAKE PADS .

Note. After replacing the brake pads, press the brake pedal firmly several times while the vehicle is stationary so that the brake pads are seated properly in their normal operating position.

Remove V.A.G 1869/2.

Bleed brake system, refer to BRAKE SYSTEM, BLEEDING

Mount the wheels.

Wheel bolt tightening specification, refer to Special Tools .

Raise the vehicle.

Remove the wheels.

Remove the brake caliper with the brake pads and front brake carrier, refer to FRONT BRAKE CALIPER WITH BRAKE CARRIER .

Note. Do not let the brake caliper with the brake carrier hang from the brake hose. Secure it to the body with suitable cable ties or wire. Do not support the weight with the brake hose.

Remove the securing bolt -arrow- on the brake rotor while holding the rotor firmly.

Scheme 14

Remove the brake rotor.

Note. When removing the brake rotor from the wheel hub, do not tilt the disc.

Clean the brake rotor, wheel hub and contact surfaces before installing.

Place the brake rotor on the hub.

Note. When positioning the brake rotor, do not tilt it on the wheel hub.

Install the securing bolt -arrow- and tighten.

Install the brake caliper with the brake pads and front brake carrier, refer to FRONT BRAKE CALIPER WITH BRAKE CARRIER .

Mount the wheels.

Wheel bolt tightening specification, refer to Special Tools .

FRONT BRAKE ROTOR, REPLACING

Note. Always replace on both axles. Always use new bolts .

Raise the vehicle.

Remove the wheels.

Remove the front brake pads, refer to BRAKE PADS .

Note. Do not let the brake caliper hang from the brake hose. Secure it to the body with suitable cable ties or wire. Do not support the weight with the brake hose.

Remove the bolts -5- on the front brake carrier.

Remove the front brake carrier.

Remove the securing bolt -arrow- on the brake rotor while holding the rotor firmly.

Remove the brake rotor.

Note. When removing the brake rotor from the wheel hub, do not tilt the disc.

Note. Always use new bolts.

Clean the brake rotor, wheel hub and contact surfaces before installing.

Place the brake rotor on the hub.

Note. When positioning the brake rotor, do not tilt it on the wheel hub.

Install the securing bolt -arrow- and tighten.

Position the front brake carrier.

Install the bolts -5- on the front brake carrier and tighten.

Install the front brake pads, refer to BRAKE PADS .

Note. After replacing the brake pads, press the brake pedal firmly several times while the vehicle is stationary so that the brake pads are seated properly in their normal operating position.

Mount the wheels.

Wheel bolt tightening specification, refer to Special Tools .

Raise the vehicle.

Remove the wheels.

Remove the front brake rotor, refer to FRONT BRAKE ROTOR .

Remove the bolts -2- on the brake shield.

Remove the brake shield.

Installation is performed in reverse sequence.

Mount the wheels.

Wheel bolt tightening specification, refer to Special Tools .

FRONT BRAKE PADS

Note. Always replace on both axles.

Special tools and workshop equipment required

1. Torque Wrench 5-50 Nm V.A.G 1331
2. Reversible Ratchet V.A.G. 1331/1
3. Piston Resetting Tool T10145

Raise the vehicle.

Remove the wheels.

Note. When removing, mark brake pads that will be used again. Install in the same position, otherwise braking effect will be uneven!

Free up the brake hose on the bracket -4-.

Scheme 15

Release the electrical wire from the bracket -2- toward the left -A- and remove.

Press the retaining spring -8- in the center.

Note. The spring is tensioned, keep hands protected. When removing the spring, make sure it does not scratch the brake caliper or damage the paint.

Remove the retaining spring carefully.

Disconnect the left front brake pad wear indicator connector.

Note. Only the inner brake pad in the left front brake caliper has a brake pad wear indicator.

Loosen and remove both guide pin bolts -4- from the brake caliper.

Pull both guide pins out of the brake caliper slightly to make it easier to remove the caliper.

Remove the brake caliper.

Note. Do not let the brake caliper hang from the brake hose. Secure it to the body with suitable cable ties or wire. Do not support the weight with the brake hose.

Remove brake pads from brake caliper housing or from brake carrier.

Clean brake caliper.

Note. Clean brake caliper with mineral spirits exclusively. Before inserting new brake pads, press the piston back into the cylinder using the piston resetting tool. Before pushing back the piston, siphon some of the brake fluid out of the brake fluid reservoir. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage.

Press piston back.

Use the T10145.

Remove any protective film from the brake pad backing plate.

Insert the inner brake pad with the retaining springs in the brake caliper. The retaining spring -arrow- must sit in the brake piston.

Scheme 16

Insert the outer brake pad -2- into the brake caliper.

Scheme 17

Note. The brake pad has a mount -10- on the backing plate that must sit firmly in the brake caliper hole.

Carefully slide the brake caliper with brake pads over the brake rotor.

Tighten the brake caliper on the brake carrier with both guide pins -4-.

Press the retaining spring in the center and insert the center tab of the retaining spring in the hole -arrow- on the brake caliper.

Note. The retaining spring -8- tab must sit correctly in the hole in the brake caliper or it can spring out and the brake pad will not be held in place. The spring is tensioned, keep hands protected. When removing the spring, make sure it does not scratch the brake caliper or damage the paint.

Insert the left front brake pad wear indicator connector in the bracket.

Insert the electrical wire in the bracket -2- and engage it to the right -B-.

Insert the brake hose in the bracket -4-.

Connect the left front brake pad wear indicator connector.

Mount the wheels, refer to Special Tools .

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

Check brake fluid level, and fill if necessary.

Raise the vehicle.

Remove the wheels.

Remove the front brake rotor, refer to FRONT BRAKE ROTOR .

Remove the bolts from the brake shield.

Remove the brake shield.

Installation is performed in reverse sequence.

Mount the wheels.

Wheel bolt tightening specification, refer to [ Special Tools .

Note. Use new bolts.

Special tools and workshop equipment required

1. Torque Wrench 40-200 Nm V.A.G 1332
2. Reversible Ratchet V.A.G. 1332/1

Raise the vehicle.

Remove the wheels.

Free up the brake hose on the bracket -4-.

Release the electrical wire from the bracket -2- toward the left -A- and remove.

Remove the bolts -1- from the brake carrier.

Remove the brake caliper with brake pads and the brake carrier.

Note. Do not let the brake caliper with the brake carrier hang from the brake hose. Secure it to the body with suitable cable ties or wire. Do not support the weight with the brake hose.

Note. Use new bolts.

Carefully press the brake caliper with the brake carrier and the brake pads installed over the brake rotor.

Tighten the brake carrier with new bolts -1-.

Insert the brake hose in the bracket -4-.

Insert the electrical wire in the bracket -2- and engage it to the right -B-.

Mount the wheels.

Wheel bolt tightening specification, refer to Special Tools .

Lower the vehicle.

Note. Use new bolts.

Special tools and workshop equipment required

1. Torque Wrench 40-200 Nm V.A.G 1332
2. Reversible Ratchet V.A.G. 1332/1
3. Torque Wrench 5-50 Nm V.A.G 1331
4. Reversible Ratchet V.A.G. 1331/1
5. Brake Pedal Actuator V.A.G 1869/2
6. Piston Resetting Tool T10145

Insert the V.A.G 1869/2 between the brake pedal and driver seat by pressing the brake pedal down at least 60 mm.

Raise the vehicle.

Remove the wheels.

Connect the hose from a bleeder bottle to one of the bleeder screws on the front caliper.

Open a bleeder screw on the front brake caliper to reduce the pressure from the brake system.

Close the bleeder screw.

Note. Do not remove brake pedal loading device V.A.G 1869/2.

Remove the brake pressure line from the brake caliper.

Remove brake pads, refer to FRONT BRAKE PADS .

Note. When removing, mark brake pads that will be used again. Install in the same position or braking effect will be uneven.

Remove the brake caliper -7- from the vehicle.

Remove the bolts -3- on the brake carrier while holding the carrier securely.

Remove the brake carrier.

Note. Use new bolts .

Position the brake carrier.

Tighten the brake carrier with new bolts -3-.

Install brake pads, refer to FRONT BRAKE PADS .

Note. After replacing the brake pads, press the brake pedal firmly several times while the vehicle is stationary so that the brake pads are seated properly in their normal operating position.

Install the brake pressure line -5- in the brake caliper and tighten.

Remove V.A.G 1869/2.

Bleed brake system, refer to BRAKE SYSTEM, BLEEDING .

Mount the wheels.

Wheel bolt tightening specification, refer to Special Tools .

Vehicle, Lifting

Remove wheels.

Remove the brake caliper with the brake pads and front brake carrier, refer to FRONT BRAKE CALIPER WITH BRAKE CARRIER .

Note. Do not let the brake caliper with the brake carrier hang from the brake hose. Secure it to the body with suitable cable ties or wire. Do not support the weight with the brake hose.

Remove the securing bolt -arrow- on the brake rotor while holding the rotor firmly.

Remove the brake rotor.

Note. When removing the brake rotor from the wheel hub, do not tilt the disc.

Clean the brake rotor, wheel hub and contact surfaces before installing.

Place the brake rotor on the hub.

Note. When positioning the brake rotor, do not tilt it on the wheel hub.

Install the securing bolt -arrow- and tighten.

Install the brake caliper with the brake pads and front brake carrier, refer to FRONT BRAKE CALIPER WITH BRAKE CARRIER .

Mount the wheels.

Wheel bolt tightening specification, refer to Special Tools .

Note. Use new bolts.

Note. Always replace on both axles.

Raise the vehicle.

Remove the wheels.

Remove the front brake pads, refer to FRONT BRAKE PADS .

Note. Do not let the brake caliper hang from the brake hose. Secure it to the body with suitable cable ties or wire. Do not support the weight with the brake hose.

Remove the bolts -3- on the front brake carrier.

Remove the front brake carrier.

Remove the securing bolt -arrow- on the brake rotor while holding the rotor firmly.

Remove the brake rotor.

Note. When removing the brake rotor from the wheel hub, do not tilt the disc.

Note. Use new bolts .

Clean the brake rotor, wheel hub and contact surfaces before installing.

Place the brake rotor on the hub.

Note. When positioning the brake rotor, do not tilt it on the wheel hub.

Install the securing bolt -arrow- and tighten.

Position the front brake carrier.

Install the bolts -3- on the front brake carrier and tighten.

Install the front brake pads, refer to FRONT BRAKE PADS .

Note. After replacing the brake pads, press the brake pedal firmly several times while the vehicle is stationary so that the brake pads are seated properly in their normal operating position.

Mount the wheels.

Wheel bolt tightening specification, refer to Special Tools .

Note. The brake caliper must not be removed to remove the brake pads. When removing, mark brake pads that will be used again. Install in the same position, otherwise braking effect will be uneven!

Raise the vehicle.

Remove the wheels.

Disconnect the brake pad wear indicator on the left brake caliper.

Remove the wear indicator wire from the left bracket.

Slide the upper and lower guide pins -10- out of the brake caliper while holding the retaining spring in place.

Remove the upper and lower springs -12-.

Press the brake pistons back with the T10145.

Note. The brake pistons with the old pads still installed can pressed back to allow all brake pistons in the brake caliper to be pressed back evenly. Before removing old brake pads, press brake piston into cylinder using resetting tool. Be careful not to damage the coating on the brake caliper. Before pushing back the piston, siphon some of the brake fluid out of the brake fluid reservoir. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage.

Remove the upper and lower brake pads from the caliper.

Clean the brake caliper housing.

Note. Clean brake caliper with mineral spirits exclusively.

Insert the upper brake pads.

Install the upper spring -12-.

Install the upper guide pin -10- into the brake caliper.

Install the lower brake pads.

Install the lower spring -12-.

Insert the lower guide pins -10- into the brake caliper.

Note. Make sure the brake pads are installed correctly inside the brake caliper.

Insert the wear indicator wire into the bracket on the left caliper.

Connect the brake pad wear indicator connector to the top of the inner left brake pad.

Mount the wheels.

Wheel bolt tightening specification, refer to Special Tools .

Check the brake fluid level and fill if necessary.

FRONT BRAKE CALIPER

Note. Replace the bolts -13-.

Note. The brake pads do not need to be removed to remove the brake caliper.

Raise the vehicle.

Remove the wheels.

Remove the brake hose from the bracket.

Insert brake pads slightly into the brake caliper.

Note. The brake pistons with the old pads still installed can pressed back to allow all brake pistons in the brake caliper to be pressed back evenly using pliers. Be careful not to damage the coating on the brake caliper and on the brake pads. Before pushing back the piston, siphon some of the brake fluid out of the brake fluid reservoir. Otherwise fluid will overflow and cause damage if the reservoir was topped off during repair work.

Hold the brake caliper steady and remove the bolts -13-.

Carefully remove the brake caliper from the brake rotor.

Note. Do not let the brake caliper hang from the brake hose. Secure it to the body with suitable cable ties or wire.

Note. Replace the bolts -13-.

Carefully press the brake caliper with brake pads installed over the brake rotor.

Tighten the brake caliper with the new bolts -13-.

Place the brake hose into the bracket.

Mount the wheels.

Wheel bolt tightening specification, refer to Special Tools .

Lower the vehicle.

Note. Replace the bolts -13-.

Insert the V.A.G 1869/2 between the brake pedal and driver seat by pressing the brake pedal down at least 60 mm.

Raise the vehicle.

Remove the wheels.

Connect the hose from a bleeder bottle to one of the bleeder screws on the front caliper.

Open a bleeder screw on the front brake caliper to reduce the pressure from the brake system.

Close the bleeder screw.

Note. Do not remove V.A.G 1869/2.

Remove brake pads, refer to BRAKE PADS .

Remove the brake hose -8- from the brake caliper.

Hold the brake caliper steady and remove the bolts -13-.

Note. Replace the bolts -13-.

Install the brake caliper using new bolts -13- and tighten.

Install the brake hose -8- in the brake caliper.

Note. Brake hose in brake caliper 16 Nm. Brake pressure line to brake hose: 16 Nm.

Install brake pads, refer to BRAKE PADS .

Remove V.A.G 1869/2.

Bleed brake system, refer to BLEEDING, WITH ELECTRONIC STABILITY PROGRAM .

Note. Bleed each brake caliper at both bleed screws.

Mount the wheels.

Wheel bolt tightening specification, refer to Special Tools .

FRONT BRAKE ROTOR

Note. Replace the bolts -1 and 13-.

Raise the vehicle.

Remove the wheels.

Push the brake pads back slightly.

Note. The brake pistons with the old pads still installed can pressed back to allow all brake pistons in the brake caliper to be pressed back evenly using pliers. Be careful not to damage the coating on the brake caliper and on the brake pads. Before pushing back the piston, siphon some of the brake fluid out of the brake fluid reservoir. Otherwise fluid will overflow and cause damage if the reservoir was topped off during repair work.

Remove the brake caliper, refer to FRONT BRAKE CALIPER .

Note. Secure the brake caliper to the vehicle with a suitable wire. Do not support the weight of the brake caliper with the brake hose.

Remove the bolt -1- from the brake rotor.

Remove the brake rotor from the wheel hub.

Note. When removing the brake rotor from the wheel hub, do not tilt the disc.

Note. Replace the bolts -1 and 13-.

Clean the brake rotor, wheel hub and contact surfaces before installing.

Place the brake rotor on the hub.

Note. When positioning the brake rotor, do not tilt it on the wheel hub.

Install the new bolt -1- and tighten it to 9 Nm.

Install the brake caliper, refer to FRONT BRAKE CALIPER .

Mount the wheels.

Wheel bolt tightening specification, refer to Special Tools .

Note. Replace the bolts -1 and 13-.

Note. Must always be replaced together on both sides of axle

Raise the vehicle.

Remove the wheels.

Remove brake pads, refer to BRAKE PADS .

Remove the brake caliper, refer to FRONT BRAKE CALIPER .

Note. Secure the brake caliper to the vehicle with a suitable wire. Do not support the weight of the brake caliper with the brake hose.

Remove the bolt -1- on the brake rotor.

Remove the brake rotor from the wheel hub.

Note. When removing the brake rotor from the wheel hub, do not tilt the disc.

Note. Replace the bolts -1 and 13-.

Clean the brake rotor, wheel hub and contact surfaces with brake cleaner before installing.

Place the brake rotor on the hub.

Note. When positioning the brake rotor, do not tilt it on the wheel hub.

Install the new bolt -1- and tighten it to 9 Nm.

Install the brake caliper, refer to FRONT BRAKE CALIPER .

Install brake pads, refer to BRAKE PADS .

Note. Before moving vehicle, depress brake pedal several times firmly to properly seat brake pads in their normal operating position.

Mount the wheels.

Wheel bolt tightening specification, refer to Special Tools .

DISENGAGING

Disengage the left and right springs -A- first from the guide bolts -B- with pliers.

Scheme 18

Pull the springs -A- then out of the brake pads -C-.

ENGAGING

First install the left and right springs -A- into the lower hole in each brake pad -C-.

Then engage them into the left and right guide pins -B- with pliers.

Making sure the springs -arrows- are installed correctly.

Note. brake caliper must not be removed in order to remove brake pads. When removing, mark brake pads that will be used again. Install in the same position, otherwise braking effect will be uneven! Check the ceramic brake rotors for damage and wear each time the brake pads are changed.

1. Ceramic Brake Rotor, Checking for Damage, refer to «CERAMIC BRAKE ROTORS, EVALUATING»(/audi/a5/i-2007-2011/remont/anti-locktraction-control/#general-technical-data-brake-system-coupe__ceramic-brake-rotors-evaluating) .
2. Ceramic Brake Rotor, Checking for Wear, refer to «CERAMIC BRAKE ROTORS, DETERMINING WEAR»(/audi/a5/i-2007-2011/remont/anti-locktraction-control/#general-technical-data-brake-system-coupe__ceramic-brake-rotors-determining-wear) .

Raise the vehicle.

Remove the wheels.

Secure the brake rotor with a wheel bolt.

Disconnect brake wear indicator connector, see illustration.

Scheme 19

Release the connector from the retainer using a screwdriver and simultaneously turn the connector 90°.

Scheme 20

Pull connector out upward and unhook line.

Note. brake caliper must not be removed in order to remove brake pads.

Disengage the left and right balance springs -A- first from the guide bolts -B- with pliers.

Pull the balance spring -A- then out of the brake pads -C-.

Remove the screw for the guide bolts -B-.

Remove the guide bolts from the brake pads and brake caliper.

Disengage the brake pad wear wire from the spring -2-.

Note. Before removing old brake pads, press brake piston into cylinder using resetting tool. Before pushing back the piston, siphon some of the brake fluid out of the brake fluid reservoir. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage.

Remove the spring -2-.

Remove brake pads from brake caliper housing.

Note. Clean brake caliper with mineral spirits exclusively.

Insert brake pads in brake caliper.

Note. The brake pad with wear indicator cable sits inside.

Install the spring inside the brake caliper housing -2-.

Slide the guide bolt -3- through the brake caliper and the brake pads.

Tighten the screw for the guide bolt -18- to the tightening specification.

Insert the left and right balance springs -A- into the hole in the bottom of the brake pads first -C-.

Then engage the left and right balance springs -A- into the guide bolts -B- with pliers.

Balance springs installed correctly to the guide bolts and brake pads -arrows-.

Connect the connector for wear indicator and hook line into dust cap and cover.

Note. Make sure the brake pad wear wire is installed in the spring -2-.

Install the brake pad wear wire into the spring -2-.

Install the wheels, refer to Special Tools .

Check brake fluid level, and fill if necessary.

BRAKE CALIPER

Note. Do not loosen the bolts -1- to remove the brake caliper.

1. 4 - Brake Caliper Do not hang on brake hose during necessary installation steps, but rather secure to body with wire.
2. 10 - Bolts NOTE: Always replace if removed. 196 Nm.
3. 11 - Brake Carrier Attach to wheel bearing housing. Bolted to the brake caliper. 190 Nm.
4. 13 - Bracket Bolt 25 Nm
5. 16 - Bracket for Brake Line Hook in brake line.

Note. Do not loosen the bolts -1- to remove the brake caliper.

Remove the brake line bracket.

Remove both bolts from the brake carrier -10-.

remove brake caliper. The brake carrier -11- remains on the brake caliper.

Installation is performed in reverse sequence.

Note. Make sure the brake hose is not twisted.

Note. When removing, mark brake pads that will be used again. Install in the same position, otherwise braking effect will be uneven! Observe the direction of rotation when installing brake rotor -arrow on brake rotor- and installed location -left or right-.

Raise the vehicle.

Remove the wheels.

Remove brake pads, refer to BRAKE PADS .

Remove the bolts -10-.

Remove the brake caliper.

Note. Replace Bolts

Slide the brake caliper over the brake rotor.

Install the bolts -10- and tighten them to 196 Nm.

Install brake pads, refer to BRAKE PADS .

Bleed brake system, refer to BRAKE SYSTEM, BLEEDING .

Mount the wheels, refer to Special Tools .

Check brake fluid level, and fill if necessary.

Vehicle, Lifting

Remove wheels.

Remove the brake caliper at the screw -10-.

Note. Do not let the brake caliper with the brake carrier hang from the brake hose. Secure it to the body with suitable cable ties or wire. Do not support the weight with the brake hose.

Note. Do not loosen the bolts -1- to remove the brake caliper.

Remove the securing bolt -6- on the brake rotor while holding the rotor firmly.

Remove the brake rotor from the wheel hub.

Note. When removing the brake rotor from the wheel hub, do not tilt the disc.

Clean the contact surfaces on the wheel hub and brake rotor. Remove any corrosion.

Place the brake rotor on the hub.

Note. When positioning the brake rotor, do not tilt it on the wheel hub.

Install the securing bolt -6- and tighten it to 5 Nm.

Install the brake caliper.

Mount the wheels.

Wheel bolt tightening specification, refer to Special Tools .

CERAMIC BRAKE ROTOR, REPLACING

Note. Always replace on both axles.

Vehicle, Lifting

Remove wheels.

Brake pads, removing

Remove the brake caliper.

Note. Do not let the brake caliper hang from the brake hose. Secure it to the body with suitable cable ties or wire. Do not support the weight with the brake hose.

Remove the securing bolt -6- on the brake rotor while holding the disc firmly.

Remove the brake rotor from the wheel hub.

Note. When removing the brake rotor from the wheel hub, do not tilt the disc.

Clean the contact surface on the wheel hub. Remove any corrosion.

Place the brake rotor on the hub.

Note. When positioning the brake rotor, do not tilt it on the wheel hub.

Install the securing bolt -6- and tighten it to 5 Nm.

Install the brake caliper.

Install the brake pads.

Mount the wheels.

Wheel bolt tightening specification, refer to Special Tools .

Raise the vehicle.

Remove the wheels.

Push the brake pads back slightly.

Note. The brake pistons with the old pads still installed can pressed back to allow all brake pistons in the brake caliper to be pressed back evenly using pliers. Be careful not to damage the coating on the brake caliper and on the brake pads. Before pushing back the piston, siphon some of the brake fluid out of the brake fluid reservoir. Otherwise fluid will overflow and cause damage if the reservoir was topped off during repair work.

Remove the brake caliper, refer to BRAKE CALIPER .

Remove the brake rotor, refer to CERAMIC BRAKE ROTOR .

Remove the bolts -9- from the brake shield.

Remove the brake shield.

Note. Replace the bolts.

Attach the brake shield -8- with new bolts -9- and tighten to 9 Nm.

Install the brake rotor, refer to CERAMIC BRAKE ROTOR .

Replace the bolts.

Note. When positioning the brake rotor, do not tilt it on the wheel hub.

Install the new bolt -6- into the brake rotor and tighten it.

Install the brake caliper, refer to BRAKE CALIPER .

Install the wheels, refer to Special Tools .

Check brake fluid level, and fill if necessary.

REAR BRAKE PADS

Special tools and workshop equipment required

1. Torque Wrench 5-50 Nm V.A.G 1331
2. Socket Wrench 21 mm V.A.G 1331/3
3. Vehicle Diagnostic TesterVAS 5051B or VAS 5052

Note. When removing, mark brake pads that will be used again. Install in the same position, otherwise braking effect will be uneven! Operating the electromechanical parking brake again after a long drive is recommended. Brake pad play is automatically adjusted every 1000 km if the EPB is not operated in this distance.

Connect the vehicle diagnostic tester or to the 16-pin diagnostic connector in the vehicle with the ignition switched off.

Scheme 21

Note. Turn on the ignition. Release the parking brake. Coding check and reported if necessary. DTC memory interrogated, errors shown corrected and DTC memory erased.

Select the parking brake with "address word" 53.

Displayed on the vehicle diagnostic tester display.

Scheme 22

Select function "053 - Parking brake".

Select the function "006 - Basic setting".

Displayed on the vehicle diagnostic tester display.

Scheme 23

1. The request to enter a display group number appears in display field -1-.
2. An entry keypad is shown in display field -2-.

Using the entry keypad, enter in display field -2- the "7" for the display group number and confirm by pressing the "Q button". (Reset pistons).

To exit the entry template, press the green arrow button at the lower left.

Switch off the ignition.

Raise the vehicle.

Remove the wheels.

Remove the brake hose and electrical wire from the bracket on the stub axle carrier.

Remove attachment bolts from brake caliper housing, counter-hold guide pins to do so.

Scheme 24

Note. Actuator or brake system connector must not be disconnected (otherwise, a fault will be saved). Do not pull on brake hose or electrical wiring.

Remove the brake caliper.

Note. Do not let the brake caliper hang from the brake hose. Secure it to the body with suitable cable ties or wire. Do not support the weight with the brake hose.

Remove the brake pads.

Remove the brake pad retaining plate.

Press piston back.

Use T10145.

Do not tilt the brake piston when pressing it back.

Note. Clean brake caliper with mineral spirits exclusively.

Insert the brake pad retaining springs.

Scheme 25

Remove any protective film from the brake pad backing plate.

Install the brake pads.

Scheme 26

Make sure that the brake pads are seated correctly in the retaining plates -arrows-.

Scheme 27

Note. The brake pads must be seated between both securing tabs on the pad retaining plate to provide the air gap between the brake rotor and brake pad.

Position the brake caliper.

Note. The repair kit includes new self-locking hex that must be installed in all cases.

Secure brake caliper using new self-locking bolts.

To tighten the bolts use V.A.G 1331 with V.A.G 1331/3.

Install the brake hose and electrical wire into the bracket on the stub axle carrier.

Note. Make sure the brake hose is correctly installed and secured inside the bracket on the stub axle carrier. So that the brake hose does not come out of the bracket on its own.

Turn on the ignition.

Displayed on the vehicle diagnostic tester display.

1. The request to enter a display group number appears in display field -1-.
2. An entry keypad is shown in display field -2-.

Using the entry keypad, enter in display field -2- the "006" for the display group number and confirm by pressing the "Q button". (guide pistons together).

To exit the entry template, press the green arrow button at the lower left.

Note. DTC memory interrogated, errors shown corrected and DTC memory erased.

Disconnect the vehicle diagnostic tester from the 16-pin diagnostic connector in the vehicle with the ignition switched off.

Mount the wheels, refer to Special Tools .

Check the brake fluid level and fill if necessary.

Raise the vehicle.

Remove the wheels.

Remove the rear brake rotor, refer to REAR BRAKE ROTOR .

Remove the bolts from the brake shield.

Remove the brake shield.

Position the brake shield.

Install the bolts on the brake shield and tighten them.

Install the rear brake rotor, refer to REAR BRAKE ROTOR .

Install the brake hose and electrical wire into the bracket on the stub axle carrier.

Note. Make sure the brake hose is correctly installed and secured inside the bracket on the stub axle carrier. So that the brake hose does not come out of the bracket on its own.

Mount the wheels.

Wheel bolt tightening specification, refer to Special Tools .

Lower the vehicle.

Special tools and workshop equipment required

1. Torque Wrench 40-200 Nm V.A.G 1332
2. Reversible Ratchet V.A.G. 1332/1
3. Vehicle Diagnostic TesterVAS 5051B
4. Pawl adapter

Connect the vehicle diagnostic tester to the 16-pin diagnostic connector in the vehicle with the ignition switched off.

Note. Turn on the ignition. Release the parking brake. Coding check and reported if necessary. DTC memory interrogated, errors shown corrected and DTC memory erased.

Select the parking brake with "address word" 53.

Displayed on the vehicle diagnostic tester display.

Select function "053 - Parking brake".

Select the function "006 - Basic setting".

Displayed on the vehicle diagnostic tester display.

1. The request to enter a display group number appears in display field -1-.
2. An entry keypad is shown in display field -2-.

Using the entry keypad, enter in display field -2- the "7" for the display group number and confirm by pressing the "Q button". (Reset pistons).

To exit the entry template, press the green arrow button at the lower left.

Switch off the ignition.

Raise the vehicle.

Remove the wheels.

Remove the brake hose and electrical wire from the bracket on the stub axle carrier.

Remove the bolts on the brake carrier -16 and 17-.

Remove the brake caliper with brake pads and the brake carrier.

Note. Do not let the brake caliper with the brake carrier hang from the brake hose. Secure it to the body with suitable cable ties or wire. Do not support the weight with the brake hose.

Note. Use new bolts.

Carefully press the brake caliper with the brake carrier and the brake pads installed over the brake rotor.

Tighten the brake carrier with new bolts -16 and 17-.

Note. Use an extension to tighten the lower screw -16-. An extension is not needed to tight the upper screw -17-. Slightly move the wheel housing liner away.

Install the brake hose and electrical wire into the bracket on the stub axle carrier.

Note. Make sure the brake hose is correctly installed and secured inside the bracket on the stub axle carrier. So that the brake hose does not come out of the bracket on its own.

Mount the wheels.

Lower the vehicle.

Wheel bolt tightening specification, refer to Special Tools .

Turn on the ignition.

Displayed on the vehicle diagnostic tester display.

1. The request to enter a display group number appears in display field -1-.
2. An entry keypad is shown in display field -2-.

Using the entry keypad, enter in display field -2- the "006" for the display group number and confirm by pressing the "Q button". (guide pistons together).

To exit the entry template, press the green arrow button at the lower left.

Note. DTC memory interrogated, errors shown corrected and DTC memory erased.

Disconnect the vehicle diagnostic tester from the 16-pin diagnostic connector in the vehicle with the ignition switched off.

REAR BRAKE CALIPER, REPLACING

Note. Use new bolts. When replacing the rear brake caliper, the actuator must not be removed. The new brake caliper is delivered with a new actuator.

Special tools and workshop equipment required

1. Torque Wrench 5-50 Nm V.A.G 1331
2. Box End Insert Tool V.A.G. 1331/3
3. Brake Pedal Actuator V.A.G 1869/2
4. Vehicle diagnostic testerVAS 5051B or VAS 5052

Connect the vehicle diagnostic tester to the 16-pin diagnostic connector in the vehicle with the ignition switched off.

Note. Turn on the ignition. Release the parking brake. Coding check and reported if necessary. DTC memory interrogated, errors shown corrected and DTC memory erased.

Select the parking brake with "address word" 53.

Displayed on the vehicle diagnostic tester display.

Select function "053 - Parking brake".

Select the function "006 - Basic setting".

Displayed on the vehicle diagnostic tester display.

1. The request to enter a display group number appears in display field -1-.
2. An entry keypad is shown in display field -2-.

Using the entry keypad, enter in display field -2- the "7" for the display group number and confirm by pressing the "Q button". (Reset pistons).

Switch off the ignition.

Insert V.A.G 1869/2 between the brake pedal and driver seat by pressing the brake pedal down at least 60 mm.

Raise the vehicle.

Remove the wheels.

Connect the hose from a bleeder bottle to one of the bleeder screws on the rear caliper.

Open a bleeder screw on the rear brake caliper to reduce the pressure from the brake system.

Close the bleeder screw.

Note. Do not remove V.A.G 1869/2.

Disconnect the parking brake connector.

Remove the brake hose and electrical wire from the bracket on the stub axle carrier.

Remove the rear brake pads, refer to REAR BRAKE PADS .

Note. When removing, mark brake pads that will be used again. Install in the same position, otherwise braking effect will be uneven! Operating the electromechanical parking brake again after a long drive is recommended. Brake pad play is automatically adjusted every 1000 km if the EPB is not operated in this distance.

Remove the brake pressure line from the brake caliper.

Remove the brake caliper from the vehicle.

Note. When replacing the rear brake caliper, the actuator must not be removed. The new brake caliper is delivered with a new actuator.

Note. Use new bolts.

Install the brake line in the brake caliper and tighten.

Install the rear brake pads, refer to REAR BRAKE PADS .

Tighten the brake caliper with the new bolts -4-.

To tighten the bolts -4- use V.A.G 1331 and V.A.G 1331/3.

Note. Reconnect the parking brake connector only after tightening the bolts.

Connect the electrical connector to the parking brake.

Install the brake hose and electrical wire into the bracket on the stub axle carrier.

Note. Make sure the brake hose is correctly installed and secured inside the bracket on the stub axle carrier. So that the brake hose does not come out of the bracket on its own. After replacing the brake pads, press the brake pedal firmly several times while the vehicle is stationary so that the brake pads are seated properly in their normal operating position.

Remove V.A.G 1869/2.

Bleed brake system, refer to BRAKE SYSTEM, BLEEDING .

Mount the wheels.

Wheel bolt tightening specification, refer to Special Tools .

Lower the vehicle.

Turn on the ignition.

Displayed on the vehicle diagnostic tester display.

1. The request to enter a display group number appears in display field -1-.
2. An entry keypad is shown in display field -2-.

Using the entry keypad, enter in display field -2- the "006" for the display group number and confirm by pressing the "Q button". (guide pistons together).

To exit the entry template, press the green arrow button at the lower left.

Note. DTC memory interrogated, errors shown corrected and DTC memory erased.

Disconnect the vehicle diagnostic tester from the 16-pin diagnostic connector in the vehicle with the ignition switched off.

Raise the vehicle.

Remove the wheels.

Remove the brake hose and electrical wire from the bracket on the stub axle carrier.

Note. Actuator or brake system connector must not be disconnected (otherwise, a fault will be saved). Do not pull on brake hose or electrical wiring.

Remove the brake caliper with the brake pads and brake carrier, refer to REAR BRAKE CALIPER WITH BRAKE CARRIER .

Note. Do not let the brake caliper with the brake carrier hang from the brake hose. Secure it to the body with suitable cable ties or wire. Do not support the weight with the brake hose.

Remove the securing bolt -arrow- on the brake rotor while holding the disc firmly.

Remove the brake rotor from the wheel hub.

Note. When removing the brake rotor from the wheel hub, do not tilt the disc.

Clean the brake rotor, wheel hub and contact surfaces before installing.

Place the brake rotor on the hub.

Note. When positioning the brake rotor, do not tilt it on the wheel hub.

Install the securing bolt -arrow- and tighten.

Install the brake caliper with brake carrier, refer to REAR BRAKE CALIPER WITH BRAKE CARRIER .

Install the brake hose and electrical wire into the bracket on the stub axle carrier.

Note. Make sure the brake hose is correctly installed and secured inside the bracket on the stub axle carrier. So that the brake hose does not come out of the bracket on its own.

Mount the wheels.

Wheel bolt tightening specification, refer to Special Tools .

Lower the vehicle.

Raise the vehicle.

Remove the wheels.

Remove the brake hose and electrical wire from the bracket on the stub axle carrier.

Note. Actuator or brake system connector must not be disconnected (otherwise, a fault will be saved). Do not pull on brake hose or electrical wiring.

Remove the rear brake pads, refer to REAR BRAKE PADS .

Remove the bolts -16 and 17- and remove the brake carrier.

Remove the securing bolt -arrow- while holding the brake rotor in place.

Remove the brake rotor from the wheel hub.

Note. When removing the brake rotor from the wheel hub, do not tilt the disc.

Clean the brake rotor, wheel hub and contact surfaces before installing.

Place the brake rotor on the hub.

Note. When positioning the brake rotor, do not tilt it on the wheel hub.

Install the securing bolt -arrow- and tighten.

Install the rear brake carrier. Install and tighten the bolts -16 and 17-.

Note. Use an extension to tighten the lower screw -16-. An extension is not needed to tight the upper screw -17-. Slightly move the wheel housing liner away.

Install the rear brake pads, refer to REAR BRAKE PADS .

Install the brake hose and electrical wire into the bracket on the stub axle carrier.

Note. Make sure the brake hose is correctly installed and secured inside the bracket on the stub axle carrier. So that the brake hose does not come out of the bracket on its own.

Mount the wheels.

Wheel bolt tightening specification, refer to Specifications .

Lower the vehicle.

BRAKE PEDAL, AUTOMATIC TRANSMISSION

Special tools and workshop equipment required

1. Release Tool for Brake Light Switch T40168.
2. Release Tool T10006
3. Torque Wrench V.A.G 1410

Remove the driver side instrument panel cover -1 to 3-.

Scheme 28

Disconnect the connector -C- on the footwell vent.

Scheme 29

Remove the footwell vent -A-.

Remove the brake lamp sensor, refer to BRAKE LAMP SENSOR .

Separate the brake pedal from brake booster, refer to BRAKE PEDAL AND BRAKE BOOSTER, DISCONNECTING AND CONNECTING .

Remove the bolt -11-.

Remove the retainer -5- and remove the pins -4- to the left.

Note. If possible, leave the brake pedal stop -17- installed; it could break the mount for the brake lamp sensor -10- if the brake pedal is released too quickly.

Be careful not to damage the stop -17- on the brake pedal. The brake lamp sensor mount -10- could break when the brake pedal is unlocked.

Slide the left retainer -12- onto the pins.

Slide the pins from left to right through the axle in the brake pedal.

Secure the pins with the right retainer -5-.

Note. The pins must be secured with the securing clips -5 and 12- on both sides.

Install and tighten the bolt -11-.

Note. Clip the brake pedal to the brake booster.

Hold the push rod ball head in front of the mount and push the brake pedal toward the brake booster, so that the ball head clicks into place.

Install the brake lamp sensor, refer to BRAKE LAMP SENSOR .

Install the footwell vents -A-B-.

Connect the connector -C- on the footwell vent.

Install the driver side instrument panel cover -1 to 3-.

MOUNTING BRACKET, AUTOMATIC TRANSMISSION

Special tools and workshop equipment required

1. Torque Wrench 5-50 Nm V.A.G 1331
2. Spring CompressorV.A.S 5122
3. Release Tool for Brake light switch T40168.
4. Release Tool T40136

Remove the driver side instrument panel cover -1 to 3-.

Disconnect the connector -C- on the footwell vent.

Remove the footwell vents -A-B-.

Remove the brake lamp sensor, refer to BRAKE LAMP SENSOR .

Disconnect the connector from the accelerator pedal module.

Separate the brake pedal from the brake booster, refer to BRAKE PEDAL AND BRAKE BOOSTER, DISCONNECTING AND CONNECTING .

Remove the tower brace.

Remove the plenum chamber bulkhead, refer to Removal and Installation .

Remove the cover -2- over the brake fluid reservoir.

Scheme 30

The cover -2- is not installed on all vehicle models.

Remove the bolts mounting the brake booster -1- to the mounting bracket.

Scheme 31

Remove the nuts -16- on the mounting bracket guides.

Turn the steering wheel with the steering wheel adjustment as far as possible to the rear, toward the driver seat.

Move the steering wheel into the straight-ahead position The vehicle wheels are in the straight-ahead position as well.

Note. It is not necessary to remove the instrument cluster and steering in order to remove the steering column.

Remove the lower bolts -2- on the steering column.

Scheme 32

Remove the lower bolts -2 through 4- for the steering column and mounting bracket.

Scheme 33

Unclip the gap cover -2- from the upper trim -1- for the steering column switch module (SMLS) -arrow A-.

Scheme 34

Remove the cable guides on the steering column.

Note. The steering is not shown in the illustration because it is not necessary to remove the steering wheel and instrument cluster.

Remove the steering column bolts -1 and 2- on the central tube while supporting the steering column from below with the hand.

Scheme 35

Note. Loosen and remove the bolts -1 and 2- with a pawl with a 3/8" drive and socket and extension.

Pull the steering column out of the steering shaft.

Carefully lay down the steering column and steering wheel.

Remove the mounting bracket from the vehicle.

Note. Replace all bolts.

Make sure the wall seal is seated properly before inserting the mounting bracket.

Install the mounting bracket into the guides in the vehicle.

Tighten the nuts on the bracket guides.

Install the bolts from the brake booster -1- to the mounting bracket and tighten them.

Note. First tighten the brake booster bolts on the bracket.

Tighten the nuts -16- on the mounting bracket guides.

Connect the electrical connector to the gas pedal module.

Note. Clip the brake pedal to the brake booster.

Hold the push rod ball head in front of the mount and push the brake pedal toward the brake booster, so that the ball head clicks into place.

Install the brake lamp sensor, refer to BRAKE LAMP SENSOR .

Push the steering column -1- on the steering shaft -3-.

Note. Use new bolts.

Position the steering column on the central tube and then install new bolts, refer to Removal and Installation .

Note. There are different bolt lengths, refer to Removal and Installation .

Tighten the bolts -1 and 2 - diagonally to 20 Nm, refer to Specifications .

Note. Use a pawl with a 3/8" drive and socket and extension to install the bolts.

Tighten the bolts -1 and 2- diagonally to 20 Nm using V.A.G 1331 and V.A.S 5122 with an extension.

Install the gap cover for the steering column switch module upper trim.

Install the cable guides on the steering column.

Tighten the bolt on the steering shaft -2- to 30 Nm + 90° turn, refer to Specifications .

Note. Use new bolts.

Install the lower bolts -1 through 4- for the steering column and bracket and then tighten them diagonally to 20 Nm, refer to Specifications .

Install the footwell vent -A-.

Connect the connector -C- on the footwell vent.

Install the driver side instrument panel cover -1 to 3-.

Install the cover -2- over the brake fluid reservoir.

The cover -2- is not installed on all vehicle models.

Install the plenum chamber bulkhead, refer to Removal and Installation .

Install the tower brace, refer to Removal and Installation .

REMOVE

Note. To remove the brake pedal on vehicles with a manual transmission, the mounting bracket must be removed.

Remove the mounting bracket, refer to MOUNTING BRACKET, MANUAL TRANSMISSION .

Note. Remove the brake pedal on the removed mounting bracket.

Special tools and workshop equipment required

1. Torque Wrench V.A.G 1410

Remove the bolt -3-.

Scheme 36

Remove the retainer -1- on the left side and remove the pins -5- to the right.

Remove brake pedal.

INSTALL

Note. Install the brake pedal on the removed mounting bracket.

Note. If possible, leave the brake pedal stop -17- installed; it could break the mount for the brake lamp sensor -10- if the brake pedal is released too quickly.

Be careful not to damage the stop -17- on the brake pedal. The brake lamp sensor mount -10- could break when the brake pedal is unlocked.

Slide the right retainer onto the pins.

Slide the pins from right to left through the axle in the brake pedal.

Secure the pins with the left retainer -1-.

Note. The pins must be secured with the retainers on both sides.

Install and tighten the bolt -3-.

Install the mounting bracket, refer to MOUNTING BRACKET, MANUAL TRANSMISSION .

MOUNTING BRACKET, MANUAL TRANSMISSION

Special tools and workshop equipment required

Scheme 37

1. Torque Wrench V.A.G 1331
2. Spring Compressor V.A.S 5122
3. Release Tool for Brake Light Switch T40168.
4. Release Tool T10006

Remove the driver side instrument panel cover -1 to 3-.

Disconnect the connector -C- on the footwell vent.

Remove the footwell vents -A-B-.

Remove the brake lamp sensor, refer to BRAKE LAMP SENSOR .

Disconnect the connector from the accelerator pedal module.

Separate the brake pedal from the brake booster, refer to BRAKE PEDAL AND BRAKE BOOSTER, DISCONNECTING AND CONNECTING .

Remove the over-center spring -2- on the clutch pedal -1- .

Scheme 38

Note. When re-installing later, make sure the over-center spring is installed correctly.

Remove the pins in the clutch pedal -4- to the clutch master cylinder from the pedal arm -3-.

Scheme 39

Note. Unlatch the lock -1 and 2 - only when it is removed.

Release the clutch master cylinder 3355.

Rotate the tool clockwise -arrow-.

Scheme 40

Remove the tower brace.

Remove the plenum chamber bulkhead, refer to Removal and Installation .

Remove the cover -2- over the brake fluid reservoir.

The cover -2- is not installed on all vehicle models.

Remove the bolts mounting the brake booster -1- to the mounting bracket.

Remove the nuts -16- on the mounting bracket guides.

Turn the steering wheel with the steering wheel adjustment as far as possible to the rear, toward the driver seat.

Move the steering wheel into the straight-ahead position The vehicle wheels are in the straight-ahead position as well.

Note. It is not necessary to remove the instrument cluster and steering in order to remove the steering column.

Remove the lower bolts -2- on the steering column.

Remove the lower bolts -2 through 4- for the steering column and mounting bracket.

Unclip the gap cover -2- from the upper trim -1- for the steering column switch module -arrow A-.

Remove the cable guides on the steering column.

Note. The steering wheel is not shown in the illustration. It is not necessary to remove the steering wheel and instrument cluster.

Remove the steering column bolts -1 and 2- on the central tube while supporting the steering column from below with the hand.

Note. Loosen and remove the bolts -1 and 2- with a pawl with a 3/8" drive and socket and extension.

Pull the steering column out of the steering shaft.

Carefully lay down the steering column and steering wheel.

Remove the mounting bracket from the vehicle.

The clutch master cylinder remains in the vehicle.

Note. Replace all bolts.

Make sure the seal on the clutch master cylinder is seated properly before inserting the mounting bracket.

Install the mounting bracket into the guides in the vehicle.

Guide the clutch master cylinder through the opening on the mounting bracket while slightly turning it to the right so that the cylinder mount fits through mounting bracket.

Tighten the nuts on the bracket guides.

Install the bolts from the brake booster -1- to the mounting bracket and tighten them.

Note. First tighten the brake booster bolts on the bracket.

Tighten the nuts -16- on the mounting bracket guides.

Engage the clutch master cylinder in the mounting bracket 3355.

Rotate the tool counter-clockwise -arrow B- while pulling the master cylinder forward -arrow-.

Scheme 41

Slide the pins -4- in the clutch pedal to the clutch master cylinder in and press them in until they are flush.

Make sure the pins are in the correct location. The groove on the pin -B- must align with the groove in the pedal arm.

Install the over-center spring -2- on the clutch pedal .

Connect the electrical connector to the gas pedal module.

Note. Clip the brake pedal to the brake booster.

Hold the push rod ball head in front of the mount and push the brake pedal toward the brake booster, so that the ball head clicks into place.

Install the brake lamp sensor, refer to BRAKE LAMP SENSOR .

Push the steering column -1- on the steering shaft -3-.

Note. Use new bolts.

Position the steering column on the central tube and insert the bolts, refer to Removal and Installation .

Note. There are different bolt lengths, refer to Removal and Installation .

Tighten the bolts -1 and 2 - diagonally to 20 Nm.

Note. Install the bolts -1 and 2- with a pawl with a 3/8" drive and socket and extension.

Tighten the bolts -1 and 2- diagonally to 20 Nm using V.A.G 1331 and V.A.S 5122 with an extension.

Install the gap cover for the steering column switch module upper trim.

Install the cable guides on the steering column.

Tighten the bolt on the steering shaft -2- to 30 Nm +90° turn, refer to Specifications .

Note. Use new bolts.

Install the lower bolts -1 through 4- for the steering column and bracket and then tighten them diagonally to 20 Nm, refer to Specifications .

Install the footwell vents -A-B-.

Connect the connector -C- on the footwell vent.

Install the driver side instrument panel cover -1 to 3-.

Install the cover -2- over the brake fluid reservoir.

The cover -2- is not installed on all vehicle models.

Install the plenum chamber bulkhead, refer to Removal and Installation .

Install the tower brace, refer to Removal and Installation .

BRAKE BOOSTER PLUNGER MOUNT

Special tools and workshop equipment required

1. Release Tool for Brake Light Switch T40168.
2. Release Tool T10006

Remove the driver side instrument panel cover -1 to 3-.

Disconnect the connector -C- on the footwell vent.

Remove the footwell vents -A-B-.

Remove the brake lamp sensor -10-, refer to BRAKE LAMP SENSOR .

Separate the brake pedal from brake booster, refer to BRAKE PEDAL AND BRAKE BOOSTER, DISCONNECTING AND CONNECTING .

Pry the brake booster plunger mount -15- out of the brake pedal using a suitable tool.

Note. If possible, leave the brake pedal stop -17- installed; it could break the mount for the brake lamp sensor -10- if the brake pedal is released too quickly.

Insert the brake booster mount and ball socket in the brake pedal.

The mount must engage audibly.

Note. Clip the brake pedal to the brake booster.

Hold the push rod ball head in front of the mount and push the brake pedal toward the brake booster until the ball head engages audibly.

Install the brake lamp sensor, refer to BRAKE LAMP SENSOR .

Install the footwell vents -A-B-.

Connect the connector -C- on the footwell vent.

Install the driver side instrument panel cover -1 to 3-.

BRAKE PEDAL AND BRAKE BOOSTER, DISCONNECTING AND CONNECTING

Note. Separate the brake pedal from the brake booster.

Special tools and workshop equipment required

1. Release Tool for Brake Light Switch T40168.
2. Release Tool T10006

Remove the driver side storage compartment -1 to 3-.

Disconnect the connector -C- on the footwell vent.

Remove the footwell vents -A-B-.

Remove the brake lamp sensor, refer to BRAKE LAMP SENSOR .

First move the brake pedal toward the brake booster and the hold it in this position.

1 - Brake Pedal

2 - Pressure Rod

3 - Retaining tabs.

Insert the T10006 as illustrated and pull it toward the driver seat. Counter-hold the brake pedal while doing this. (At this moment the pedal must not move backward). The mounting retaining lugs -3- will thereby be pressed off the ball head of the push rod -2-.

For ease of illustration separating the brake pedal from the brake booster is shown with the pedal assembly removed.

Pull T10006 and brake pedal together toward the driver seat. (This will pull the brake pedal off the push rod ball head).

Note. Connect the brake pedal to the brake booster.

Note. If possible, leave the brake pedal stop -17- installed; it could break the mount for the brake lamp sensor -10- if the brake pedal is released too quickly.

Be careful not to damage the stop -17- on the brake pedal. The brake lamp sensor mount -10- could break when the brake pedal is unlocked.

Hold the push rod ball head in front of the mount and push the brake pedal toward the brake booster, so that the ball head clicks into place.

Scheme 42

Install the brake lamp sensor, refer to BRAKE LAMP SENSOR .

Install the footwell vent -A-.

Connect the connector -C- on the footwell vent.

Install the driver side storage compartment -1 to 3-.

ELECTROMECHANICAL PARKING BRAKE CONTROL MODULE -J540

Special tools and workshop equipment required

1. Torque Wrench V.A.G 1410

Fold up the right rear side trim in the luggage compartment, refer to Removal and Installation .

A trailer mode control module may be installed depending on the model. The trailer mode control module and the bracket for the module must be removed before removing the electronic parking brake control module.

Remove the nuts.

Slide the electrical connector lock -2- forward.

Scheme 43

Remove the electronic parking brake control module -1- with the plug connector.

Remove the electrical connector from the control module.

Remove the control module from the vehicle.

Connect the electrical connector -2- on the control module.

Slide the retainer on the connector back and lock it.

Insert the control module.

Install the nuts and tighten to 9 Nm.

Install the trailer mode control module and bracket, if applicable. Bracket, 3 Nm.

If the electronic parking brake control module is replaced, select the "Replace" function for the respective control module in "Guided Fault Finding".

Note. Use the vehicle diagnostic tester.

ELECTROMECHANICAL PARKING BRAKE ACTUATOR

Special tools and workshop equipment required

1. Torque Wrench 5-50 Nm V.A.G 1331
2. Vehicle Diagnostic Tester

Note. Ignition on Release the parking brake. DTC memory interrogated, errors shown corrected and DTC memory erased. Ignition off.

Raise the vehicle.

Remove the wheels.

Note. Ignition must be switched off for at least 30 seconds when disconnecting connector! Clean the entire area around the connector and actuator/brake caliper. Disconnect actuator connector -1-.

Remove both actuator bolts -1-.

Scheme 44

Remove the actuator in the direction of the arrow.

Scheme 45

Remove sealing ring with a suitable tool.

Scheme 46

Note. Make sure that ring groove of the seal and contact surface of parking brake actuator do not become damaged. Do not use any tools with sharp edges.

Clean ring groove and contact surfaces if dirty. Only use brake cleaner.

Install new seal.

Turn the brake caliper adjuster screw -1- back slightly.

Scheme 47

Note. This makes it easier to install the actuator.

Position the actuator.

Note. Make sure that the seal is seated correctly.

2- Then rotate actuator so bolt hole -a- and threads in brake caliper housing -b- line up.

Scheme 48

Note. Make sure that parking brake actuator is seated flush against the brake caliper.

Attach both actuator bolts (Torx® 30). Tightening specification: 12 Nm.

Scheme 49

Note. Position bolts by hand and screw in a few turns. If threads are damaged, entire brake caliper must be replaced!

Note. Only insert connector by hand to avoid damaging it. Make sure that connectors on vehicle side and actuator side are free of dirt and damage.

Install connector.

Mount the wheels, refer to Special Tools .

Note. After replacing actuator, basic setting 006 must be performed with the vehicle diagnostic tester in the EPB function. Use vehicle diagnostic tester.

then select Basic Setting 006 under "Function".

Under chassis (Repair Group 01:34-65).

Brake system (Repair Group 01:45-46).

01 - On Board Diagnostic (OBD) capable systems.

J540 - Electro-Mechanical Parking Brake Control Module.

J540 - Basic setting (3 electrical parking brake function test).

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 50

Scheme 51

1. Release Tool for Brake Light Switch T40168.
2. Release Tool T10006
3. Torque Wrench V.A.G 1410
4. Torque Wrench 5-50 Nm V.A.G 1331
5. Vehicle Diagnostic Tester

See also:
• BRAKES PR CODES
• BRAKE CALIPER, SERVICING, 1LT
• General Information
• General Information
• CERAMIC BRAKE ROTORS, EVALUATING
• CERAMIC BRAKE ROTORS, DETERMINING WEAR
• Special Tools
• BRAKE LAMP SENSOR
• Parking Brake Switch -F321
• REAR BRAKE CALIPER PISTON
• BRAKE SYSTEM, BLEEDING
• BLEEDING, WITH ELECTRONIC STABILITY PROGRAM
• Removal and Installation
• Removal and Installation
• Removal and Installation
• Removal and Installation
• BRAKE PADS
• FRONT BRAKE ROTOR
• FRONT BRAKE PADS
• FRONT BRAKE ROTOR
• FRONT BRAKE CALIPER
• BRAKE CALIPER
• CERAMIC BRAKE ROTOR, REPLACING
• Electromechanical Parking Brake Control Module -J540
• ELECTROMECHANICAL PARKING BRAKE ACTUATOR
• REAR BRAKE CALIPER, REPLACING
• REAR BRAKE PADS
• MOUNTING BRACKET, MANUAL TRANSMISSION
• MOUNTING BRACKET, AUTOMATIC TRANSMISSION
• BRAKE PEDAL, AUTOMATIC TRANSMISSION
• BRAKE BOOSTER PLUNGER MOUNT
• FRONT BRAKE CALIPER WITH BRAKE CARRIER
• BRAKE PEDAL AND BRAKE BOOSTER, DISCONNECTING AND CONNECTING