Mechanical Components - Brake System Audi Q5 I

BRAKE PEDAL AND MOUNTING BRACKET, OVERVIEW

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

Scheme 1

1. Mounting Bracket for Pedal Assembly Illustration for vehicles with automatic transmission. Removing and Installing, with Manual Transmission, refer to «MOUNTING BRACKET, WITH MANUAL TRANSMISSION»(/audi/q5/i-2008-2012/remont/mechanical-hydraulic/#mechanical-components-brake-system__mounting-bracket-with-manual-transmission) . Removing and Installing, with Automatic Transmission, refer to «MOUNTING BRACKET, WITH AUTOMATIC TRANSMISSION»(/audi/q5/i-2008-2012/remont/mechanical-hydraulic/#mechanical-components-brake-system__mounting-bracket-with-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. Bolt 8 Nm
10. Brake Pedal Position Sensor -G100- Only for hybrid vehicles. Removing and installing, refer to «BRAKE PEDAL POSITION SENSOR -G100»(/audi/q5/i-2008-2012/remont/mechanical-hydraulic/#mechanical-components-brake-system__brake-pedal-position-sensor-g100) .
11. Brake Lamp Sensor Removing and Installing, refer to «BRAKE LAMP SENSOR»(/audi/q5/i-2008-2012/remont/anti-locktraction-control/#anti-lock-brake-system__brake-lamp-sensor) .
12. Magnet Carrier Only for hybrid vehicles. For the brake pedal position sensor. The centering pin -arrow- must audibly engage when installing at the brake pedal.
13. Pedal Support Bolt 20 Nm
14. Mounting Pin Bolt The bolt holds the mounting pins in position. 8 Nm
15. Left Securing Clip (Spring Steel)
16. Brake Pedal Removing and Installing, with Manual Transmission, refer to «BRAKE PEDAL, WITH MANUAL TRANSMISSION»(/audi/q5/i-2008-2012/remont/mechanical-hydraulic/#mechanical-components-brake-system__brake-pedal-with-manual-transmission) . Removing and Installing, with Automatic Transmission. refer to «BRAKE PEDAL, WITH AUTOMATIC TRANSMISSION»(/audi/q5/i-2008-2012/remont/mechanical-hydraulic/#mechanical-components-brake-system__brake-pedal-with-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.
17. Ball Socket Formed in Mount For the ball head on the brake booster push rod.
18. 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/q5/i-2008-2012/remont/mechanical-hydraulic/#mechanical-components-brake-system__brake-booster-plunger-mount) .
19. Nut 8 Nm
20. 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.
21. Grommet Only installed on vehicles with automatic transmission.

Scheme 2

1. Parking Brake Contact Switch -F321- The switch is always illuminated so it can be found in the dark. Pull the close button to "engage the parking brake". Press the --> open button. It is necessary to press the foot brake. Installed location: in the center console. Removing and Installing, refer to «ELECTRO-MECHANICAL PARKING BRAKE SWITCH»(/audi/q5/i-2008-2012/remont/anti-locktraction-control/#anti-lock-brake-system__electro-mechanical-parking-brake-switch) .
2. LED (Light Emitting Diode) Installed location: in the parking brake contact 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. Electro-Mechanical Parking Brake Function Lights 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 Right Brake Caliper Removing and Installing, refer to «ELECTRO-MECHANICAL PARKING BRAKE ACTUATOR»(/audi/q5/i-2008-2012/remont/mechanical-hydraulic/#mechanical-components-brake-system__electro-mechanical-parking-brake-actuator) . Brake Caliper, Removing and Installing, refer to «REAR BRAKE CALIPER WITH BRAKE CARRIER, REMOVING AND INSTALLING»(/audi/q5/i-2008-2012/remont/mechanical-hydraulic/#mechanical-components-brake-system__rear-brake-caliper-with-brake-carrier) .
6. Electro-Mechanical Parking Brake Control Module -J540- Installed location: in the right rear side panel behind the side trim. Removing and Installing, refer to «ELECTRO-MECHANICAL PARKING BRAKE CONTROL MODULE J540»(/audi/q5/i-2008-2012/remont/mechanical-hydraulic/#mechanical-components-brake-system__electro-mechanical-parking-brake-control-module-j540) . 9 Nm
7. Electrical Parking Brake Actuator with Left Brake Caliper Removing and Installing, refer to «ELECTRO-MECHANICAL PARKING BRAKE ACTUATOR»(/audi/q5/i-2008-2012/remont/mechanical-hydraulic/#mechanical-components-brake-system__electro-mechanical-parking-brake-actuator) . Brake Caliper, Removing and Installing, refer to «REAR BRAKE CALIPER WITH BRAKE CARRIER, REMOVING AND INSTALLING»(/audi/q5/i-2008-2012/remont/mechanical-hydraulic/#mechanical-components-brake-system__rear-brake-caliper-with-brake-carrier) .
8. Acoustic Signal Warning if it is operated while driving greater than 7 km/h. Warning when a malfunction is detected in the system.

FRONT BRAKES, FBC-60, OVERVIEW

Applies to Hybrid Vehicles

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.

Scheme 3

1. Brake Pads Wear limit, refer to «BRAKES»(/audi/q5/i-2008-2012/remont/anti-locktraction-control/#general-technical-data-brake-system__brakes) . 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, FBC-60, REMOVING AND INSTALLING»(/audi/q5/i-2008-2012/remont/mechanical-hydraulic/#mechanical-components-brake-system__front-brake-pads-fbc-60-removing-and) . Check the brake pad thickness. 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. 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 NOTE: Do not twist it when installing.
6. Bolt 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, FBC-60, REMOVING AND INSTALLING»(/audi/q5/i-2008-2012/remont/mechanical-hydraulic/#mechanical-components-brake-system__front-brake-pads-fbc-60-removing-and) , "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 Do not remove. WARNING: 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»(/audi/q5/i-2008-2012/remont/anti-locktraction-control/#general-technical-data-brake-system__brakes) . Must always be replaced together on both sides of axle. Removing and Installing, refer to «FRONT BRAKE DISC, FBC-60, REMOVING AND INSTALLING»(/audi/q5/i-2008-2012/remont/mechanical-hydraulic/#mechanical-components-brake-system__front-brake-disc-fbc-60-removing-and) . Coat contact surfaces between brake disc and wheel hub with Polycarbamide grease G 052 142 A2, refer to «General Information»(/audi/q5/i-2008-2012/remont/wheel-tire-system/#wheels-tires-wheel-alignment-general-information) .
12. Brake Pad Bolt 5 Nm

REAR BRAKES WITH ELECTRONIC PARKING BRAKE, OVERVIEW

Rear Wheel Brake with Automatic Adjustment

Note. Only install the complete repair set.

Scheme 4

1. Self-Locking Bolt 12 Nm
2. Electromechanical Parking Brake Actuator Electromechanical parking brake control module, removing and installing, refer to «ELECTRO-MECHANICAL PARKING BRAKE CONTROL MODULE J540»(/audi/q5/i-2008-2012/remont/mechanical-hydraulic/#mechanical-components-brake-system__electro-mechanical-parking-brake-control-module-j540) . Actuator, removing and installing, refer to «ELECTRO-MECHANICAL PARKING BRAKE ACTUATOR»(/audi/q5/i-2008-2012/remont/mechanical-hydraulic/#mechanical-components-brake-system__electro-mechanical-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. NOTE: Do not twist it when installing.
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, REMOVING AND INSTALLING»(/audi/q5/i-2008-2012/remont/mechanical-hydraulic/#mechanical-components-brake-system__rear-brake-caliper-with-brake-carrier) . Replace, refer to «REAR BRAKE CALIPER, REPLACING»(/audi/q5/i-2008-2012/remont/mechanical-hydraulic/#mechanical-components-brake-system__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, REMOVING AND INSTALLING»(/audi/q5/i-2008-2012/remont/mechanical-hydraulic/#mechanical-components-brake-system__rear-brake-caliper-with-brake-carrier) .
9. Brake Pads Wear limit, refer to «BRAKES»(/audi/q5/i-2008-2012/remont/anti-locktraction-control/#general-technical-data-brake-system__brakes) . Must always be replaced together on both sides of axle. Removing and Installing, refer to «REAR BRAKE PADS, REMOVING AND INSTALLING»(/audi/q5/i-2008-2012/remont/mechanical-hydraulic/#mechanical-components-brake-system__rear-brake-pads-removing-and-installing) . Check the 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 disc 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 disc and brake pad.
11. Wheel Bolts Mounting wheels, refer to «General Information»(/audi/q5/i-2008-2012/remont/wheel-tire-system/#wheels-tires-wheel-alignment-general-information) . 140 Nm
12. Bolt 5 Nm
13. Brake Rotor Wear limit, refer to «BRAKES»(/audi/q5/i-2008-2012/remont/anti-locktraction-control/#general-technical-data-brake-system__brakes) . Removing and Installing, refer to «REAR BRAKE DISC, REMOVING AND INSTALLING»(/audi/q5/i-2008-2012/remont/mechanical-hydraulic/#mechanical-components-brake-system__rear-brake-disc-removing-and-installing) . Must always be replaced together on both sides of axle. Brake rotor allocation, refer to «BRAKES»(/audi/q5/i-2008-2012/remont/anti-locktraction-control/#general-technical-data-brake-system__brakes) .
14. Hex Head Bolts 10 Nm
15. Brake Shield Removing and Installing, refer to «REAR BRAKE SHIELD, REMOVING AND INSTALLING»(/audi/q5/i-2008-2012/remont/mechanical-hydraulic/#mechanical-components-brake-system__rear-brake-shield-removing-and-installing) .
16. Bolt 100 Nm + 90° turn Always replace if removed.
17. Bolts 100 Nm + 90° turn Always replace if removed.

FASTENER TIGHTENING SPECIFICATIONS

BRAKE CALIPER WITH FRONT BRAKE CARRIER, FBC-60, REMOVING AND INSTALLING

Use new bolts.

Removing

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-.

Scheme 5

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

Remove the bolts -1- on 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.

Installing

Use new bolts.

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

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-.

Install wheels.

Wheel bolt tightening specifications, refer to Specifications .

Lower vehicle.

FRONT BRAKE CALIPER, FBC-60, REPLACING

Use new bolts.

Removing

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 brake pedal actuator V.A.G 1869/2 between the brake pedal and driver seat by pressing the brake pedal down at least 60mm. By doing this, the valves in the brake master cylinder are closed and the brake fluid reservoir does not run empty.

Scheme 6

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 the brake pressure line from the brake caliper.

Remove brake pads, refer to FRONT BRAKE PADS, FBC-60, REMOVING AND INSTALLING

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.

Installing

Use new bolts.

Position the brake carrier.

Tighten the brake carrier with new bolts -3-.

Install brake pads, refer to FRONT BRAKE PADS, FBC-60, REMOVING AND INSTALLING .

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 the V.A.G 1869/2.

Bleed brake system, refer to BRAKE SYSTEM, BLEEDING .

Install wheels.

Wheel bolt tightening specifications, refer to Specifications .

FRONT BRAKE PADS, FBC-60, REMOVING AND INSTALLING

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!

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

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.

Installing

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 using the T10145.

Scheme 7

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 8

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

Scheme 9

Press the brake pad and mount into the hole in the brake caliper.

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 disc.

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

Position the retaining spring -8- on the outer brake pad.

Press the retaining spring -8- in the center and insert the center tab of the retaining spring in the hole -arrow- on the brake caliper.

Note. The retaining spring 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.

Install the wheels, refer to Specifications .

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.

FRONT BRAKE DISC, FBC-60, REMOVING AND INSTALLING

Removing

Raise and support vehicle.

Remove wheels.

Remove the brake caliper with the brake pads and front brake carrier, refer to BRAKE CALIPER WITH FRONT BRAKE CARRIER, FBC-60, REMOVING AND INSTALLING .

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 disc while holding the disc firmly.

Scheme 10

Remove the brake rotor.

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

Installing

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

Place the brake disc 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 BRAKE CALIPER WITH FRONT BRAKE CARRIER, FBC-60, REMOVING AND INSTALLING .

Install the wheels.

Wheel bolt tightening specifications, refer to Specifications .

FRONT BRAKE DISC, FBC-60, REPLACING

Use new bolts.

Note. Always replace on both axles.

Removing

Raise the vehicle.

Remove the wheels.

Remove the front brake pads, refer to FRONT BRAKE PADS, FBC-60, REMOVING AND INSTALLING .

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 disc while holding the disc firmly.

Remove the brake rotor.

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

Installing

Use new bolts.

Clean the brake disc, 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.

Note. Do not angle the brake carrier with mounting it.

Install the screws -3- on the front brake carrier and tighten to the tightening specification.

Install the front brake pads, refer to FRONT BRAKE PADS, FBC-60, REMOVING AND INSTALLING .

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 wheels.

Wheel bolt tightening specifications, refer to Specifications .

FRONT BRAKE SHIELD, FBC-60, REMOVING AND INSTALLING

Removing

Raise the vehicle.

Remove the wheels.

Remove the front brake disc, refer to FRONT BRAKE DISC, FBC-60, REMOVING AND INSTALLING .

Remove the bolts on the brake shield.

Remove the brake shield.

Installing b

Installation is performed in reverse sequence.

Install wheels.

Wheel bolt tightening specifications, refer to Specifications .

REAR BRAKE CALIPER WITH BRAKE CARRIER, REMOVING AND INSTALLING

Removing

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 Tester
4. Pawl adapter

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

Scheme 11

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

Select function "053 - Parking brake".

Select the function "006 - Basic setting".

Display on vehicle diagnostic tester

Scheme 12

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 "007" for the display group number and confirm by pressing the "Q button". (Reset pistons).

To exit the entry template, press the green arrow button on 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.

Installing

Use new bolts

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

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 and wiring is correctly attached and secured inside the bracket on the stub axle carrier. This will prevent the hose and wiring from coming out of the bracket.

Install wheels.

Lower the vehicle.

Wheel bolt tightening specifications, refer to Specifications .

Switch on the ignition.

Display on vehicle diagnostic tester

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 on 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

Use new bolts.

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

Removing

Special tools and workshop equipment required

1. Torque Wrench 5-50 Nm V.A.G 1331
2. Socket Tool V.A.G. 1331/3
3. Brake Pedal Actuator V.A.G 1869/2
4. Vehicle Diagnostic Tester

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

Note. Switch on the ignition. Parking brake released. Coding check and reported if necessary. DTC memory interrogated, errors shown corrected and DTC memory erased.

Select function "053 - Parking brake".

Select the function "006 - Basic setting".

Display on vehicle diagnostic tester

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 "007" for the display group number and confirm by pressing the "Q button". (Reset pistons).

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

Switch off the ignition.

Insert the V.A.G 1869/2 between the brake pedal and driver seat by pressing the brake pedal down at least 60mm. By doing this, the valves in the brake master cylinder are closed and the brake fluid reservoir does not run empty.

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 the 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, REMOVING AND INSTALLING .

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.

Installing

Use new bolts

Install the brake line in the brake caliper and tighten.

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

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 and wiring is correctly attached and secured inside the bracket on the stub axle carrier. This will prevent the hose and wiring from coming out of the bracket. 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 the V.A.G 1869/2.

Bleed brake system, refer to BRAKE SYSTEM, BLEEDING .

Install wheels.

Wheel bolt tightening specifications, refer to Specifications .

Lower the vehicle.

Switch on the ignition.

Display on vehicle diagnostic tester

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 on 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 PADS, REMOVING AND INSTALLING

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 Tester

Removing

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

Note. Switch on the ignition. Parking brake released. Coding check and reported if necessary. DTC memory interrogated, errors shown corrected and DTC memory erased.

Select function "053 - Parking brake".

Select the function "006 - Basic setting".

Display on vehicle diagnostic tester

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 "007" for the display group number and confirm by pressing the "Q button". (Reset pistons).

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

Switch off the ignition.

Raise the vehicle.

Dismount tires.

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 13

Note. 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 the T10145.

Do not tilt the brake piston when pressing it back.

Installing

Note. Clean brake caliper with mineral spirits exclusively.

Insert the brake pad retaining springs.

Scheme 14

Remove any protective film from the brake pad backing plate.

Insert brake pads.

Scheme 15

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

Scheme 16

Note. The brake pads must be seated between both securing tabs on the pad retaining plate to provide the air gap between the brake disc 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 and wiring is correctly attached and secured inside the bracket on the stub axle carrier. This will prevent the hose and wiring from coming out of the bracket.

Install wheels.

Lower the vehicle.

Wheel bolt tightening specifications, refer to Specifications .

Check the brake fluid level and fill if necessary.

Switch on the ignition.

Display on vehicle diagnostic tester

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 on 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 DISC, REMOVING AND INSTALLING

Removing

Raise the vehicle.

Remove the wheels.

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

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

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 disc while holding the disc firmly.

Remove the brake disc from the wheel hub.

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

Installing

Note. Replace bolts.

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

Place the brake disc 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, REMOVING AND INSTALLING .

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 and wiring is correctly attached and secured inside the bracket on the stub axle carrier. This will prevent the hose and wiring from coming out of the bracket.

Install wheels.

Wheel bolt tightening specifications, refer to Specifications .

Lower vehicle.

REAR BRAKE DISC, REPLACING

Removing

Raise the vehicle.

Remove the wheels.

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, REMOVING AND INSTALLING .

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

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

Remove the brake disc from the wheel hub.

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

Installing

Note. Replace bolts.

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

Place the brake disc 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 the bolts -16 and 17- and tighten to 100 Nm + 90° additional turn.

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, REMOVING AND INSTALLING .

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

Note. Make sure the brake hose and wiring is correctly attached and secured inside the bracket on the stub axle carrier. This will prevent the hose and wiring from coming out of the bracket.

Install the wheels.

Wheel bolt tightening specifications, refer to Specifications .

Lower vehicle.

REAR BRAKE SHIELD, REMOVING AND INSTALLING

Removing

Raise the vehicle.

Remove the wheels.

Remove the rear brake disc, refer to REAR BRAKE DISC, REMOVING AND INSTALLING .

Remove the bolts on the brake shield.

Remove the brake shield.

Installing

Position the brake shield.

Install the bolts on the brake shield and tighten them.

Install the rear brake disc, refer to REAR BRAKE DISC, REMOVING AND INSTALLING .

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

Note. Make sure the brake hose and wiring is correctly attached and secured inside the bracket on the stub axle carrier. This will prevent the hose and wiring from coming out of the bracket.

Install wheels.

Wheel bolt tightening specifications, refer to Specifications .

Lower vehicle.

BRAKE PEDAL AND BRAKE BOOSTER, DISCONNECTING AND CONNECTING

Special tools and workshop equipment required

1. Release Tool for Brake Light Switch T40168.
2. Release Tool T40136

Disconnect the Brake Pedal from the Brake Booster

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

Scheme 17

Disconnect the connector -C- on the footwell vent.

Scheme 18

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.

Scheme 19

1 - Brake Pedal

2 - Pressure Rod

3 - Retaining tabs.

Insert the T40136 and pull in the direction of the driver seat as illustrated. When doing this, counter-hold at the brake pedal (the pedal must not be allowed to move backward at this time). 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 T40136 and brake pedal together toward the driver seat. (This will pull the brake pedal off the push rod ball head).

Connect the Brake Pedal to the Brake Booster

Scheme 20

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.

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 21

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

Install the footwell vents -A-B-.

Tighten the footwell vent screw -A-.

Connect the electrical connector to the footwell vent -C-.

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

BRAKE PEDAL, WITH AUTOMATIC TRANSMISSION

Special tools and workshop equipment required

1. Torque Wrench 5-50 Nm V.A.G 1331
2. Reversible Ratchet V.A.S 5122
3. Release Tool for Brake Light Switch T40168 A.
4. Retaining Device T40136
5. Torque Wrench V.A.G 1410

Removing

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

Disconnect the electrical connector to the footwell vent -C-.

Remove the footwell vents -A-B-.

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 bolt -11-.

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

Installing

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.

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-.

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

Install and tighten the bolt -11-.

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 BRAKE LAMP SENSOR .

Install the footwell vents -A-B-.

Tighten the footwell vent screw -A-.

Connect the electrical connector to the footwell vent -C-.

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

MOUNTING BRACKET, WITH AUTOMATIC TRANSMISSION

Applies to Hybrid Vehicles

Special tools and workshop equipment required

1. Torque Wrench 5-50 Nm V.A.G 1331
2. Reversible Ratchet V.A.S 5122
3. Release Tool for Brake Light Switch T40168 A.
4. Retaining Device T40136

Removing

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

Disconnect the electrical connector to the footwell vent -C-.

Remove the footwell vents -A-B-.

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

Disconnect the electrical connector from the gas pedal module.

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

Remove the tower brace.

Applies to Hybrid Vehicles

Remove the electrical A/C compressor high voltage cable -P3- from the plenum chamber bulkhead .

Continuation for All Vehicles

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

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

Scheme 22

The installed cover -2- depends on the model.

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

Scheme 23

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 24

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

Scheme 25

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

Scheme 26

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.

Scheme 27

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.

Installing

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

Install the mounting bracket into the guides in the vehicle.

Install the nuts on the mounting bracket guides and secure it.

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

Note. First install the bolts from the brake booster to the mounting bracket and tighten them.

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

Connect the electrical connector to the gas pedal module.

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-.

Mount the steering column onto the central tube and install the bolts.

Note. Note that the bolts have different lengths.

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 to 20 Nm with torque wrench V.A.G 1331 and spring compressor V.A.S 5122 with extension.

Mount the upper trim gap cover for the steering column switch module (SMLS).

Install the cable guides on the steering column.

Tighten the bolt on the steering shaft -2- to 20 Nm.

Install and tighten the lower bolts -1 through 4- for the steering column and mounting bracket to 20 Nm.

Install the footwell vents -A-B-.

Tighten the footwell vent screw -A-.

Connect the electrical connector to the footwell vent -C-.

Install the driver side cover -1 to 3-.

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

The installed cover -2- depends on the model.

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

Applies to Hybrid Vehicles

Attach the electrical A/C compressor high voltage cable -P3- to the plenum chamber bulkhead .

Continuation for All Vehicles

Install the tower brace, refer to Removal and Installation .

BRAKE PEDAL, WITH MANUAL TRANSMISSION

Special tools and workshop equipment required

1. Torque Wrench V.A.G 1410

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

Applies to Hybrid Vehicles

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

Remove the brake pedal on the removed mounting bracket.

Remove the bolt -3-.

Scheme 28

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

Remove brake pedal.

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.

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, WITH MANUAL TRANSMISSION .

Applies to Hybrid Vehicles

MOUNTING BRACKET, WITH MANUAL TRANSMISSION

Special tools and workshop equipment required

1. Torque Wrench 5-50 Nm V.A.G 1331
2. Reversible Ratchet V.A.S 5122
3. Release Tool for Brake Light Switch T40168 A.
4. Release Tool T40136

Applies to Hybrid Vehicles

Removing

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

Disconnect the electrical connector to the footwell vent -C-.

Remove the footwell vents -A-B-.

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

Disconnect the electrical connector from the gas pedal module.

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

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

Scheme 29

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.

Scheme 30

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

Release the clutch master cylinder 3355.

Rotate the tool clockwise -arrow-.

Scheme 31

Remove the tower brace.

Applies to Hybrid Vehicles

Remove the electrical A/C compressor high voltage cable -P3- from the plenum chamber bulkhead .

Continuation for All Vehicles

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

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

Note. The installed cover -2- depends on the model.

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 (SMLS) -arrow A-.

Remove the cable guides on the steering column.

Note. the steering wheel is not shown in the illustration. Do not remove the steering and the 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.

Installing

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.

Install the nuts on the mounting bracket guides and secure it.

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

Note. First install the bolts from the brake booster to the mounting bracket and tighten them.

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 32

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.

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-.

Mount the steering column onto the central tube and install the bolts.

Note. Note that the bolts have different lengths.

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 to 20 Nm with V.A.G 1331 and V.A.S 5122 with extension.

Mount the upper trim gap cover for the steering column switch module (SMLS).

Install the cable guides on the steering column.

Tighten the bolt on the steering shaft -2- to 20 Nm.

Install and tighten the lower bolts -1 through 4- for the steering column and mounting bracket to 20 Nm.

Install the footwell vents -A-B-.

Tighten the footwell vent screw -A-.

Connect the electrical connector to the footwell vent -C-.

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

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

Note. The installed cover -2- depends on the model.

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

Applies to Hybrid Vehicles

Attach the electrical A/C compressor high voltage cable -P3- to the plenum chamber bulkhead .

Continuation for All Vehicles

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 A.
2. Release Tool T40136

Removing

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

Disconnect the electrical connector to the footwell vent -C-.

Remove the footwell vents -A-B-.

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 .

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

Installing

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

The mount must engage audibly.

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-.

Tighten the footwell vent screw -A-.

Connect the electrical connector to the footwell vent -C-.

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

BRAKE PEDAL POSITION SENSOR -G100

Removing

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

Disconnect the electrical connector to the footwell vent -C-.

Remove the footwell vents -A-B-.

Disconnect the connector -1- from the brake pedal position sensor -G100- -2-.

Scheme 33

Remove the bolts -arrows- and then remove the brake pedal position sensor -- -2-.

Installing

Insert the brake pedal position sensor -- -2- and tighten the bolts -arrows- to 8 Nm.

Connect the connector -1

Install the footwell vents -A-B-.

Tighten the footwell vent screw -A-.

Connect the electrical connector to the footwell vent -C-.

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

ELECTRO-MECHANICAL PARKING BRAKE CONTROL MODULE J540

Special tools and workshop equipment required

1. Torque Wrench V.A.G 1410

Removing

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

Scheme 34

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 35

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.

Installing

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".

Use the vehicle diagnostic tester.

ELECTRO-MECHANICAL PARKING BRAKE ACTUATOR

Special tools and workshop equipment required

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

Removing

Note. Ignition off. Ignition must be switched off for at least 30 seconds when disconnecting the motor connector! Parking brake released. DTC memory interrogated, errors shown corrected and DTC memory erased.

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 36

Remove the actuator in the direction of the arrow.

Scheme 37

Remove sealing ring with a suitable tool.

Scheme 38

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.

Installing

Install new seal.

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

Scheme 39

Note. This makes it easier to install the actuator.

Position the actuator.

Note. Make sure that the seal is seated correctly

Item -2- Then rotate actuator so bolt hole -a- and threads in brake caliper housing -b- are brought into alignment.

Scheme 40

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

Attach both actuator bolts (Torx® 30).

Scheme 41

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

Tighten the motor bolts. Tightening specification, 12 Nm.

Connect the connector to the motor.

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 the motor in the bracket.

Install the wheels, refer to Specifications .

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

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

Note. Ignition on Parking brake released. Coding check and reported if necessary. DTC memory interrogated, errors shown corrected and DTC memory erased.

Select function "053 - Parking brake".

Select the function "006 - Basic setting".

J540 - Electro-Mechanical Parking Brake Control Module

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

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

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 42

1. Torque Wrench V.A.G 1410
2. Retaining Device T40136
3. Torque Wrench 40-200 Nm V.A.G 1332
4. Reversible Ratchet V.A.G. 1332/1
5. Torque Wrench 5-50 Nm V.A.G 1331
6. Reversible Ratchet V.A.G. 1331/1
7. Brake Pedal Actuator V.A.G 1869/2
8. Piston Resetting Tool T10145
9. Release Tool for Brake Light Switch T40168 A A.
10. Reversible Ratchet V.A.S 5122

See also:
• BRAKE LAMP SENSOR
• ELECTRO-MECHANICAL PARKING BRAKE SWITCH
• BRAKES
• General Information
• BRAKE SYSTEM, BLEEDING
• Removal and Installation
• Removal and Installation
• Removal and Installation
• MOUNTING BRACKET, WITH MANUAL TRANSMISSION
• MOUNTING BRACKET, WITH AUTOMATIC TRANSMISSION
• BRAKE PEDAL POSITION SENSOR -G100
• BRAKE PEDAL, WITH MANUAL TRANSMISSION
• BRAKE PEDAL, WITH AUTOMATIC TRANSMISSION
• BRAKE BOOSTER PLUNGER MOUNT
• ELECTRO-MECHANICAL PARKING BRAKE ACTUATOR
• REAR BRAKE CALIPER WITH BRAKE CARRIER, REMOVING AND INSTALLING
• ELECTRO-MECHANICAL PARKING BRAKE CONTROL MODULE J540
• FRONT BRAKE PADS, FBC-60, REMOVING AND INSTALLING
• FRONT BRAKE DISC, FBC-60, REMOVING AND INSTALLING
• REAR BRAKE CALIPER, REPLACING
• REAR BRAKE PADS, REMOVING AND INSTALLING
• REAR BRAKE DISC, REMOVING AND INSTALLING
• REAR BRAKE SHIELD, REMOVING AND INSTALLING
• BRAKE CALIPER WITH FRONT BRAKE CARRIER, FBC-60, REMOVING AND INSTALLING
• BRAKE PEDAL AND BRAKE BOOSTER, DISCONNECTING AND CONNECTING