Hydraulic Components - Brake System (roadster) Audi TT 8J

FRONT BRAKE CALIPER SERVICING, FN3

Note. Install complete repair kit when servicing. New brake calipers are filled with brake fluid and are pre-bled. Apply thin coat of lithium grease G 052 150 A2 to brake cylinders, pistons and seals.

FRONT BRAKE CALIPER SERVICING, FNRG57

Note. Install complete repair kit when servicing. Apply thin coat of lithium grease G 052 150 A2 to brake cylinders, pistons and seals.

FRONT BRAKE CALIPER SERVICING, TT RS

Note. The TT RS brake caliper cannot be serviced.

REAR BRAKE CALIPER SERVICING

Note. Install complete repair kit when servicing. Only use mineral spirits to clean brake parts. New brake calipers are filled with brake fluid and are pre-bled. Apply thin coat of lithium grease G 052 150 A2 to brake cylinders, pistons and seals. In case of repair, brake calipers must always be pre-bled before being installed into vehicle (without brake pads). Refer to Pre-Bleed Brake Caliper .

BRAKE SYSTEM BLEEDING

When filling with brake fluid using e.g. brake charger/bleeder unit VAS 5234 or brake filler/bleeder unit suction adapter V.A.G 1869/4, make sure that the filling pressure does not exceed 1 bar.

Regulate brake fluid pressure on brake charger/bleeder unit to 1 bar. Refer to the VAS 5234 or V.A.G 1869/4 operating instructions.

Note. Only use new brake fluid. Rinse off any spilled brake fluid using plenty of water.

BRAKE SYSTEM, BLEEDING WITH BRAKE FILLER/BLEEDER UNIT VAS 5234 OR BRAKE FILLER/BLEEDER UNIT SUCTION ADAPTER V.A.G 1869/4

Special tools and workshop equipment required

1. Brake filler/bleeder unit VAS 5234 or
2. Brake filler/bleeder unit V.A.G 1869
3. Brake filler/bleeder unit suction adapter V.A.G 1869/4
4. Vehicle diagnostic, test and information System VAS 505x

Procedure

Connect VAS 5234 or V.A.G 1869/4.

Remove protective cap on brake caliper bleeder screw.

Connect bleeder bottle hose to brake caliper bleeder valve.

Leave the bleeder screw open, with brake fluid hose connected, until brake fluid flows out clear and free of air bubbles.

Press brake pedal 5 times to assist bleeding procedure.

Tighten bleeder screw to 10 Nm.

Remove bleeder hose and install protective cap on bleeder screw.

Repeat bleeding process on remaining brake calipers.

Bleeding Sequence

1 - Left front brake caliper

2 - Right front brake caliper

3 - Left rear brake caliper

4 - Right rear brake caliper

Fill brake fluid reservoir up to max. marking and install sealing cap.

Start engine to check brake pedal travel and pressure.

If pedal travel is too long and pressure is too weak, check brake system for possible leaks. Repeat bleeding procedure.

After bleeding brake system, perform zero adjustment on Brake Pressure Sensor 1 -G201- via the Guided Fault Finding function with the VAS 505x.

Note. A road test must be performed after bleeding. During this, at least one ABS regulation must be performed at all four wheels!

BRAKE SYSTEM, BLEEDING WITHOUT BRAKE FILLER AND BLEEDER TOOL

Note. A second person is needed to bleed the brake charger/bleeder unit.

Remove protective cap on brake caliper bleeder screw.

Connect bleeder bottle hose to brake caliper bleeder valve.

Build pressure up in brake system by pumping brake pedal.

Note. Slowly press brake pedal to prevent bubbles from forming.

As soon as pressure is built up, hold brake pedal in depressed position.

Open the bleeder screw, with bleeder bottle hose connected, until the pressure is relieved (pedal drops).

Hold pedal in completely depressed position and close the bleeder screw.

Release brake pedal and wait approximately 2 seconds so that brake fluid can flow out of the brake fluid reservoir.

Repeat the procedure until the brake fluid flows out clear and free of bubbles.

Tighten bleeder screw to 10 Nm.

Remove bleeder hose and install protective cap on bleeder screw.

Repeat bleeding process on remaining brake calipers.

Bleeding Sequence

1 - Left front brake caliper

2 - Right front brake caliper

3 - Left rear brake caliper

4 - Right rear brake caliper

Fill brake fluid reservoir up to max. marking and install sealing cap.

Start engine to check brake pedal travel and pressure.

If pedal travel is too long and pressure is too weak, check brake system for possible leaks. Repeat bleeding procedure.

Scheme 119

1. Protective Cap Install onto bleeder valve.
2. Bleeder Screw 10 Nm Apply a thin coat of lithium grease G 052 150 A2 to the threads before screwing in.
3. Caps Insert in bushing.
4. Guide Pins 30 Nm
5. Bushing Insert in brake caliper housing.
6. Brake Caliper Housing Brake caliper with a balance weight, refer to «DAMPER ON FRONT BRAKE CALIPER ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#mechanical-components-brake-system-roadster__damper-on-front-brake-caliper-assembly) .
7. Brake Carrier Bolt to brake caliper housing.
8. Retaining Spring Insert both ends into holes of brake caliper housing.
9. Seal Do not damage when installing piston. Removing and installing, refer to «FRONT BRAKE CALIPER PISTON, FN3»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#hydraulic-components-brake-system-roadster__front-brake-caliper-piston-fn3) .
10. Pistons Removing and installing, refer to «FRONT BRAKE CALIPER PISTON, FN3»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#hydraulic-components-brake-system-roadster__front-brake-caliper-piston-fn3) . Apply thin coat of lithium grease G 052 150 A2 to piston.
11. Protective Cap Pull onto piston with outer sealing lip. Do not damage when installing piston. Removing and installing, refer to «FRONT BRAKE CALIPER PISTON, FN3»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#hydraulic-components-brake-system-roadster__front-brake-caliper-piston-fn3) .

Scheme 120

1. Brake Carrier Bolt to brake caliper housing.
2. Guide Pins 30 Nm
3. Caps Insert in bushing.
4. Protective Cap Push onto bleeder valve.
5. Bleeder Valve Apply a thin coat of lithium grease G 052 150 A2 to the threads before screwing in. 15 Nm
6. Bushing Insert in brake caliper housing.
7. Brake Caliper Housing Brake caliper with a balance weight, refer to «DAMPER ON FRONT BRAKE CALIPER ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#mechanical-components-brake-system-roadster__damper-on-front-brake-caliper-assembly) .
8. Retaining Spring Observe correct installed position. Hook in at both brake caliper housing studs and at the outer brake pad retaining spring.
9. Protective Cap Do not damage when installing piston. Coat with lithium grease G 052 150 A2.
10. Pistons Apply thin coat of lithium grease G 052 150 A2 to piston beforehand.
11. Seal Coat with lithium grease G 052 150 A2.

Scheme 121

1. Bolt Self-locking Always replace after removal. When loosening and tightening, counter-hold at guide pin. 35 Nm
2. Bleeder Screw Apply a thin coat of lithium grease G 052 150 A2 to the threads before screwing in. 10 Nm
3. Protective Cap
4. Guide Pins Grease before pulling on protective cap.
5. Protective Cap Pull onto brake carrier and guide pin.
6. Brake Carrier with Guide Pins and Protective 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 supplied grease packet to lubricate guide pins.
7. Protective Cap Pull onto piston with outer sealing lip
8. Piston with Automatic Adjustment Removing and installing, refer to «REAR BRAKE CALIPER PISTON»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#hydraulic-components-brake-system-roadster__rear-brake-caliper-piston) . Apply thin coat of lithium grease G 052 150 A2 to piston.
9. Seal Do not damage when installing piston. Removing and installing, refer to «REAR BRAKE CALIPER PISTON»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#hydraulic-components-brake-system-roadster__rear-brake-caliper-piston) .
10. Brake Caliper Housing with Parking Brake Cable Lever Replace if leaking at parking brake cable lever. Pre-bleed caliper housing after repairing. Refer to «Pre-Bleed Brake Caliper»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#hydraulic-components-brake-system-roadster__pre-bleed-brake-caliper) .

BRAKE BOOSTER AND BRAKE MASTER CYLINDER ASSEMBLY OVERVIEW

Note. Brake master cylinder and brake boosters can be replaced independently of one another.

Scheme 122

1. Gasket For brake booster.
2. Brake Booster On certain vehicles, the necessary pressure is removed at the intake manifold. Vehicles with OHBV have a Brake Booster Vacuum Sensor G483 installed. Refer to «BRAKE BOOSTER VACUUM SENSOR, WITH OPTIMIZED HYDRAULIC BRAKE VACUUM (OHBV) BOOSTING»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#anti-lock-brake-system-roadster__brake-booster-vacuum-sensor-with-optimized) . Functional Check With engine switched off, depress brake pedal firmly several times (to deplete vacuum in tool). Press and hold brake pedal. Start engine. If brake booster is functioning correctly, brake pedal slackens noticeably under foot. Disconnect from brake pedal. Refer to «BRAKE PEDAL AND BRAKE BOOSTER, SEPARATING»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#mechanical-components-brake-system-roadster__brake-pedal-and-brake-booster-separating) . Removing and installing, refer to «BRAKE BOOSTER»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#hydraulic-components-brake-system-roadster__brake-booster) . Removing and installing, TT RS, refer to «BRAKE BOOSTER, TT RS»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#hydraulic-components-brake-system-roadster__brake-booster-tt-rs) NOTE: If the vehicle has a TFSI engine, then the noise amplifier must be removed and installed. Refer to «NOISE AMPLIFIER, TFSI»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#hydraulic-components-brake-system-roadster__noise-amplifier-tfsi) . If the vehicle has a TTS engine, then the noise amplifier must be removed and installed. Refer to «NOISE AMPLIFIER, TFSI»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#hydraulic-components-brake-system-roadster__noise-amplifier-tfsi) . The noise amplifier is inside the engine compartment in front of the brake booster. Replace as complete unit if malfunctioning.
3. Seal Replace
4. Brake Master Cylinder With attached brake light switch «ABS/ESP MARK 60 BRAKE SYSTEM COMPONENT AND INSTALLATION LOCATION OVERVIEW => List Item:13»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#anti-lock-brake-system-roadster) . Cannot be serviced. Replace as complete unit if malfunctioning. Removing and installing, refer to «BRAKE MASTER CYLINDER»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#hydraulic-components-brake-system-roadster__brake-master-cylinder) . Removing and installing, TT RS, refer to «BRAKE MASTER CYLINDER, TT RS»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#hydraulic-components-brake-system-roadster__brake-master-cylinder-tt-rs) NOTE: If the vehicle has a TFSI engine, then the noise amplifier must be removed and installed. Refer to «NOISE AMPLIFIER, TFSI»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#hydraulic-components-brake-system-roadster__noise-amplifier-tfsi) . If the vehicle has a TTS engine, then the noise amplifier must be removed and installed. Refer to «NOISE AMPLIFIER, TFSI»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#hydraulic-components-brake-system-roadster__noise-amplifier-tfsi) . The noise amplifier is inside the engine compartment in front of the brake booster.
5. Heat Shield
6. Nut Self-locking. Always replace after removal. 20 Nm
7. Brake Line Brake master cylinder/secondary piston circuit to hydraulic unit. 14 Nm
8. Brake Line Brake master cylinder/primary piston circuit to hydraulic control unit. 14 Nm
9. Sealing Plugs Coat with brake fluid and insert into brake master cylinder.
10. Brake Fluid Reservoir Coat with brake fluid and insert into sealing plugs in brake master cylinder. With floating insert with integrated brake fluid level warning switch. To replace the warning switch, remove brake fluid reservoir. Press brake fluid reservoir into sealing plugs. Removing and installing, refer to «BRAKE FLUID RESERVOIR»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#hydraulic-components-brake-system-roadster__brake-fluid-reservoir) .
11. Cap With integrated floater and brake fluid level warning switch.
12. Vacuum Tube With check valve.
13. Sealing Plugs

Scheme 123

Remove driver side compartment. Refer to Removal and Installation .

Make sure that boot did not slip out of the circumferential groove, as shown here.

BRAKE LINES AND BRAKE HOSES

The following will show the various installed locations and torque specifications of the brake lines and brake hoses.

Brake Lines in Area of Brake Master Cylinder/Hydraulic Unit ITT Mark 60/ ITT Mark 70

Scheme 124

1 - Brake line to brake master cylinder: 14 Nm

Brake Lines In Brake Master Cylinder/Hydraulic Unit Mark 60 Area

Scheme 125

1 - Brake line to hydraulic unit: 14 Nm

Brake Lines/Brake Hoses In Area Of Front Wheel (Fwd)

Scheme 126

1 - Hex bolt: 8 Nm

2 - Brake line: 14 Nm

3 - Securing clip

Brake Hose Connection with Anti-Rotation Device

Scheme 127

Make sure that groove in brake hose banjo fitting is inserted in securing tab -arrow-.

Tightening specifications, brake line to front brake caliper

1. Brake "16" FN-3" 35 Nm.
2. Brake "17" FNR-G57" 14 Nm.
3. Brake "TT RS" 35 Nm.

Tightening specification, brake line to rear brake caliper

1. All models: 14 Nm

Brake Line Connections

Bolt -1- 15 Nm.

Scheme 128

Brake Line Connection at Underbody

Scheme 129

1 - Brake line: 14 Nm

Brake Line/Brake Hoses in Area of Rear Axle (FWD)

Scheme 130

1 - Brake line: 14 Nm

2 - Securing clip

3 - Install clearance retainer -3- on brake caliper side.

Brake Line/Brake Hoses Near the Rear Axle

Scheme 131

1 - Brake line: 14 Nm

2 - Securing clip

4 - Install clearance retainer -4- on brake caliper side.

Line Connection of Brake Line

Scheme 132

When fastening union bolt -2-, counter-hold union nut -1-.

1. Tightening specification: 14 Nm

CHECK VALVE CHECKING, TT RS

The check valve is installed in front of the brake booster.

Note. The check valve must allow air to flow in the direction of the arrow. Valve must remain closed in opposite direction. The check valve is open in direction of the brake booster.

Check Valve, Removing and Installing, refer to CHECK VALVE, TT RS .

FASTENER TIGHTENING SPECIFICATIONS

1. 1) Always replace after removal.

HIGH AND LOW PRESSURE TESTING

Special tools and workshop equipment required

1. Brake pressure gauge 0-250 bar V.A.G 1310A
2. Brake pedal actuator V.A.G 1869/2

High Pressure Testing

Note. Brake system (brake master cylinder, brake hoses, brake lines and brake calipers) tested for function and leaks.

Remove bleeder screw at one of the front brake calipers. Connect V.A.G 1310 A and bleed.

Install V.A.G 1869/2 between brake pedal and driver seat. Apply pressure to brake pedal until the gauge indicates a pressure of 50 bar. The pressure must not drop by more than 4 bar during the test period of 45 seconds.

Replace master cylinder if pressure drops greatly.

Low Pressure Testing

Set the brake pedal loading device back far enough that the pressure gauge indicates 6 bar positive pressure.

The pressure must not drop by more than 1 bar during a test period of 3 minutes.

Replace master cylinder if pressure drop is greater.

FRONT BRAKE CALIPER PISTON, FN3

Special tools and workshop equipment required

1. Disassembly wedge 3409
2. Piston resetting tool T10145
3. Assembly device for protective cap T10146/6

Removing

Force piston from brake caliper using compressed air.

Place a wooden board into the recess of the caliper housing so it is not damaged.

Scheme 133

Pry off protective cap from brake caliper using 3409.

Scheme 134

Remove seal using 3409.

Scheme 135

When removing, make sure that surface of cylinder is not damaged.

Installing

The surface of the piston and seal must only be cleaned with mineral spirits and then dried.

Thinly coat piston and seal with lithium grease G 052 150 A2 before inserting.

Install sealing ring in brake caliper.

Insert the protective cap -A- into the T10146/6 -1-.

Scheme 136

Press the protective cap with the assembly tool -1- and the piston resetting tool -2- into the brake caliper so that it contacts the brake caliper all around.

Scheme 137

Check Seating of Protective Caps

Protective cap must no longer be able to be pulled from brake caliper by hand.

Scheme 138

Press the piston lightly against the protective cap and lock it into position, e.g. with the trim removal wedge -2-.

Blow the protective cap on with pressurized air (max. 3 bar) -1-. Protective cap springs onto piston.

Scheme 139

Note. Do not angle piston, to avoid damaging the seal sleeve.

Press piston into brake caliper using piston resetting tool -1-.

Scheme 140

Outer sealing lip of protective cap will then engage in piston groove.

FRONT BRAKE CALIPER PISTON, FNRG57

Special tools and workshop equipment required

1. Disassembly wedge 3409
2. Piston resetting tool T10145
3. Assembly tool T10146
4. Assembly device for protective cap T10146/2

Removing

Force piston from brake caliper housing using compressed air.

Scheme 141

Note. Place a wooden board into the recess of the caliper housing so it is not damaged.

Remove seal.

Scheme 142

Use the 3409 for this.

Note. When removing, make sure that surface of cylinder is not damaged.

Installing

The surface of the piston and seal must only be cleaned with mineral spirits and then dried.

Thinly coat piston and seal with lithium grease G 052 150 A2 before inserting.

Using 3409, insert the inner seal into the groove in the brake caliper.

Scheme 143

Press in the protective cap using special tool -1- and -2-.

Scheme 144

1- T10146/2

2- T10145

Use protective backings

Press the protective cap onto the brake caliper housing so that it contacts the brake caliper housing all around -arrow-.

Scheme 145

It should no longer be possible to remove the protective cap from the brake caliper housing by hand.

Thinly coat piston and seal with lithium grease G 052 150 A2 before inserting.

Lift the brake piston, as shown, with commercially available extension and ratchet adapter and lightly press against the protective cap.

Scheme 146

Do not angle piston, to avoid damaging the seal sleeve.

Blow the protective cap on with pressurized air (max. 3 bar). The protective cap will thereby jump over the brake piston.

Use protective backings

Press piston into the brake caliper housing by hand.

Note. The inner sealing lip of the protective cap thereby slips into the groove on the piston.

REAR BRAKE CALIPER PISTON

Special tools and workshop equipment required

1. Resetting and extracting tool T10165
2. Disassembly wedge 3409

Removing

Remove piston from brake caliper by turning knurled wheel toward left.

Insert piston compressing and extracting tool so collar makes contact on piston.

Scheme 147

1. For pistons that are difficult to move, an open-end wrench (size 13 mm) can be applied at the appropriate wrench surface -arrow A-.

Remove seal using 3409.

Scheme 148

Installing

The surface of the piston and seal must only be cleaned with mineral spirits and then dried.

Thinly coat piston and seal with lithium grease G 052 150 A2 before inserting.

Insert oil seal in brake caliper housing.

Place protective cap with outer sealing lip on piston.

Scheme 149

Using 3409, insert inner sealing lip into cylinder groove.

Scheme 150

Note. Hold piston in front of caliper housing for this procedure.

Set T10165 against piston of brake caliper housing.

Scheme 151

Install the piston by turning knurled wheel toward right.

Note. By resetting the piston with a piston resetting tool, the automatic adjustment in the brake caliper is destroyed. If the piston is difficult to move, use a 13 mm open end wrench on the flats -arrow- provided for this purpose.

Insert brake pads.

Pre-Bleed Brake Caliper

Open bleeder screw -arrow A- and using a standard bleeder bottle, fill with brake fluid until bubble-free brake fluid flows from the threaded hole (brake hose connection) -arrow B-. Close bleeder valve.

Scheme 152

Note. Position brake caliper as shown during pre-bleed procedure.

BRAKE FLUID RESERVOIR

Removing

On the TT RS, remove the engine cover -1- upward.

TT RS engine cover

Scheme 153

Extract any brake fluid from the reservoir.

Note. Make sure that brake fluid cannot leak out of the brake fluid reservoir because it will damage components and the paint. When siphoning brake fluid, always use a bleeder bottle that is used exclusively for brake fluid.

Pull off the clutch hose and seal it off.

Remove the bolt under the brake fluid reservoir.

Note. Depending on the model, an additional locking pin is pushed through the mount in the master brake cylinder and brake fluid reservoir.

Remove the locking pin from the master brake cylinder and the brake fluid reservoir.

Remove the brake fluid reservoir.

Installing

Coat the connections on the brake fluid reservoir with brake fluid and insert into sealing plugs in brake master cylinder.

Note. Depending on the model, an additional locking pin is pushed through the mount in the master brake cylinder and brake fluid reservoir.

Remove the locking pin from the master brake cylinder and the brake fluid reservoir.

Install the bolt under the brake fluid reservoir and tighten it.

Install the clutch hose.

Bleed the clutch. Refer to BRAKE SYSTEM BLEEDING .

Bleed brake system. Refer to BRAKE SYSTEM BLEEDING .

BRAKE MASTER CYLINDER

Note. If the vehicle has a TFSI engine, then the noise amplifier must be removed and installed. Refer to NOISE AMPLIFIER, TFSI . The noise amplifier is inside the engine compartment in front of the brake booster.

Special tools and workshop equipment required

1. Torque wrench V.A.G 1331
2. Brake filler/bleeder unit V.A.G 1869
3. Brake filler/bleeder unit suction adapter V.A.G 1869/4
4. Brake filler/bleeder unit VAS 5234
5. Sealing plugs repair kit, Part no. 1H0 698 311 A
6. Vehicle Diagnosis, Testing and Information System VAS 505x

Removing

Scheme 154

Remove engine cover upward in -direction of arrow-.

Depending on the engine installed, remove the noise amplifier. Refer to NOISE AMPLIFIER, TFSI .

Remove brake light switch. Refer to BRAKE LIGHT SWITCH .

To protect against escaping brake fluid, place enough lint-free cloths in the area below the master brake cylinder.

Extract as much brake fluid as possible from brake fluid reservoir using VAS 5234 or V.A.G 1869/4.

Connect connector on brake fluid level warning switch.

Disconnect brake lines -3- at brake master cylinder and seal brake lines with sealing plugs from repair kit.

Scheme 155

Remove brake master cylinder nuts -1-.

Remove heat shield.

Unclip brake fluid reservoir at position -2- and pull upward and off.

Remove brake master cylinder from brake booster.

Installing

Installation is the reverse of removal, with special attention to the following

Replace sealing ring between brake master cylinder and brake booster.

When replacing brake master cylinder, ensure pressure rod in brake booster is seated correctly.

Use new nuts -1-. Note torque: 20 Nm

Press brake pedal down a bit, this allows the brake master cylinder to be guided into pressure rod more easily.

Install brake lines -3- on brake master cylinder. Note torque: 14 Nm

Install brake light switch. Refer to BRAKE LIGHT SWITCH .

Install the brake fluid reservoir. Refer to BRAKE FLUID RESERVOIR .

Depending on the engine installed, install the noise amplifier. Refer to NOISE AMPLIFIER, TFSI

Brake system bleeding, refer to BRAKE SYSTEM BLEEDING .

Initiate brake pressure sensor basic setting.

Note. Use the VAS 505x for this.

Perform ESP driving and system test.

Vehicle Diagnostic Tester

Under chassis

Brake system (Repair Group 01; 45)

01- On Board Diagnostic (OBD) capable systems

03- Brake electronics ABS/ESP Mark 60 si

J104- ABS/ASR/ESP Control Module, Functions

BRAKE MASTER CYLINDER, TT RS

Removing

Special tools and workshop equipment required

1. Torque wrench V.A.G 1331
2. Brake filler/bleeder unit V.A.G 1869
3. Brake filler/bleeder unit suction adapter V.A.G 1869/4
4. Brake filler/bleeder unit VAS 5234
5. Sealing plugs repair kit, Part no. 1H0 698 311 A

Remove the engine cover -1-.

Remove bolts -arrows- and remove the air guide.

Scheme 156

Remove the bolts -arrows- and remove the air filter housing.

Scheme 157

On the TT RS remove the brake lamp switch. Refer to BRAKE LAMP SWITCH, TT RS .

To protect against escaping brake fluid, place enough lint-free cloths in the area below the master brake cylinder.

Extract as much brake fluid as possible from brake fluid reservoir using brake charger/bleeder unit VAS 5234 or extraction device upgrade kit V.A.G 1869/4.

Connect connector on brake fluid level warning switch.

Disconnect brake lines -3- at brake master cylinder and seal brake lines with sealing plugs from repair kit.

Remove brake master cylinder nuts -1-.

Remove heat shield.

Unclip brake fluid reservoir at Pos. -2- and pull upward and off.

Remove brake master cylinder from brake booster.

Installing

Installation is the reverse of removal, with special attention to the following

Replace sealing ring between brake master cylinder and brake booster.

When replacing brake master cylinder, ensure pressure rod in brake booster is seated correctly.

Use new nuts -1-. Note torque. See item 6

Press brake pedal down a bit, this allows the brake master cylinder to be guided into pressure rod more easily.

Install brake lines -3- on brake master cylinder. Note torque. See item 7

On the TT RS install the brake lamp switch. Refer to BRAKE LAMP SWITCH, TT RS .

Install the brake fluid reservoir BRAKE FLUID RESERVOIR .

Install the air filter housing and tighten the bolts -arrows-.

Install the air guide and tighten the bolts -arrows-.

Install the engine cover.

Brake System: ABS/ESP Mark 60, bleeding BRAKE SYSTEM BLEEDING .

Initiate brake pressure sensor basic setting.

Use Vehicle Diagnosis, Testing and Information System VAS 505x for this.

Perform ESP driving and system test.

Vehicle diagnostic, test and information System VAS 505x

Under chassis

Brake system (Repair Group 01; 45)

01 - On Board Diagnostic (OBD) capable systems

03- Brake electronics ABS/ESP Mark 60 si

J104- ABS/ASR/ESP Control Module, Functions

BRAKE BOOSTER

Note. If the vehicle has a TFSI engine, then the noise amplifier must be removed and installed. Refer to NOISE AMPLIFIER, TFSI . The noise amplifier is inside the engine compartment in front of the brake booster.

Scheme 158

1 - Brake Booster

2 - Brake Light Switch

1. To brake booster.

6 - Nut

1. Always replace after removal.
2. 25 Nm

8 - Brake Pedal

Special tools and workshop equipment required

1. Torque wrench V.A.G 1331
2. Brake filler/bleeder unit V.A.G 1869
3. Brake filler/bleeder unit suction adapter V.A.G 1869/4
4. Brake filler/bleeder unit VAS 5234
5. Sealing plugs repair kit, Part no. 1H0 698 311 A
6. Vehicle Diagnosis, Testing and Information System VAS 505x

Removing

Remove the vacuum in the brake booster by pressing the brake pedal repeatedly.

Depending on the engine installed, remove the noise amplifier. Refer to NOISE AMPLIFIER, TFSI .

Remove brake light switch. Refer to BRAKE LIGHT SWITCH .

Remove brake master cylinder. Refer to BRAKE MASTER CYLINDER .

Note. Remove brake booster vacuum sensor -G483- depending on model. Refer to BRAKE BOOSTER VACUUM SENSOR, WITH OPTIMIZED HYDRAULIC BRAKE VACUUM (OHBV) BOOSTING .

Unclip and remove the vacuum line from the brake booster.

Remove driver side compartment. Refer to Removal and Installation .

Disconnect brake pedal from brake booster. Refer to BRAKE PEDAL AND BRAKE BOOSTER, SEPARATING .

Remove the nuts -6-.

Remove the brake booster from the vehicle.

Installing

Installation is the reverse of removal, with special attention to the following

Note. Use new nuts.

Observe torque: 25 Nm

Clip brake pedal together with brake booster. Refer to BRAKE PEDAL AND BRAKE BOOSTER, SEPARATING .

Note. Install brake booster vacuum sensor depending on model. Refer to BRAKE BOOSTER VACUUM SENSOR, WITH OPTIMIZED HYDRAULIC BRAKE VACUUM (OHBV) BOOSTING .

Install brake master cylinder. Refer to BRAKE MASTER CYLINDER .

Install brake light switch. Refer to BRAKE LIGHT SWITCH .

Depending on the engine installed, install the noise amplifier. Refer to NOISE AMPLIFIER, TFSI .

Install driver side compartment. Refer to Removal and Installation .

Brake system bleeding, refer to BRAKE SYSTEM BLEEDING .

Initiate brake pressure sensor basic setting.

Note. Use VAS 505x for this.

Perform ESP driving and system test.

Vehicle Diagnostic Tester

Under chassis

Brake system (Repair Group 01; 45)

01- On Board Diagnostic (OBD) capable systems

03- Brake electronics ABS/ESP Mark 60si

J104- ABS/ASR/ESP Control Module, Functions

On vehicles with ABS/ESP, initiate brake pressure sensor basic setting.

Perform ESP driving and system test.

BRAKE BOOSTER, TT RS

1 - Brake Booster

2 - Brake Light Switch

1. to brake booster -- On the TT RS remove the brake lamp switch. Refer to «BRAKE LAMP SWITCH, TT RS»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#anti-lock-brake-system-roadster__brake-lamp-switch-tt-rs) .

6 -Bolt

1. 25 Nm

8 - Brake Pedal

Removing

Special tools and workshop equipment required

1. Torque wrench V.A.G 1331
2. Brake filler/bleeder unit V.A.G 1869
3. Brake filler/bleeder unit suction adapter V.A.G 1869/4
4. Brake filler/bleeder unit VAS 5234
5. Sealing plugs repair kit, Part no. 1H0 698 311 A

Remove the vacuum in the brake booster by pressing the brake pedal repeatedly.

On the TT RS remove the brake lamp switch. Refer to BRAKE LAMP SWITCH, TT RS .

On the TT RS remove the master brake cylinder. Refer to BRAKE MASTER CYLINDER, TT RS .

Note. Remove Brake Booster Vacuum Sensor G483, depending on model BRAKE BOOSTER VACUUM SENSOR, WITH OPTIMIZED HYDRAULIC BRAKE VACUUM (OHBV) BOOSTING

Remove the engine cover -1-.

Remove bolts -arrows- and remove the air guide.

Remove the bolts -arrows- and remove the air filter housing.

Unclip and remove the vacuum line from the brake booster.

Remove the vacuum line to the check valve.

Remove driver side compartment: Interior Equipment

Disconnect brake pedal from brake booster BRAKE PEDAL AND BRAKE BOOSTER, SEPARATING .

Remove the nuts -6-.

Remove the brake booster from the vehicle.

Installing

Installation is the reverse of removal, with special attention to the following

Use New Nuts.

Observe torque (Scheme 158)

Clip brake pedal together with brake booster BRAKE PEDAL AND BRAKE BOOSTER, SEPARATING .

Note. Install Brake Booster Vacuum Sensor G483, depending on model BRAKE BOOSTER VACUUM SENSOR, WITH OPTIMIZED HYDRAULIC BRAKE VACUUM (OHBV) BOOSTING

Install brake master cylinder. BRAKE MASTER CYLINDER .

On the TT RS install the brake lamp switch. Refer to BRAKE LAMP SWITCH, TT RS .

Install the vacuum line.

Connect the vacuum line to the check valve.

Install driver side compartment: Interior Equipment

Install the air filter housing and tighten the bolts -arrows-.

Install the air guide and tighten the bolts -arrows-.

Install the engine cover.

Brake System: ABS/ESP Mark 60, bleeding BRAKE SYSTEM BLEEDING .

Initiate brake pressure sensor basic setting.

Use Vehicle Diagnosis, Testing and Information System VAS 505x for this.

Perform ESP driving and system test.

Vehicle diagnostic, test and information System VAS 505x.

Under chassis

Brake system (Repair Group 01; 45)

01 - On Board Diagnostic (OBD) capable systems

03- Brake electronics ABS/ESP Mark 60si

J104- ABS/ASR/ESP Control Module, Functions

On vehicles with ABS/ESP, initiate brake pressure sensor basic setting.

Perform ESP driving and system test.

NOISE AMPLIFIER, TFSI

Note. The noise amplifier is inside the engine compartment in front of the brake booster.

Removing

Unclip the air guide for the air filter housing.

Remove air duct from air filter housing.

Remove engine cover upward in -direction of arrow-.

Remove the upper air guide from the noise amplifier.

Remove the noise amplifier off the 3 rubber buffers on the bracket.

Remove the lower air guide from the noise amplifier.

Remove the noise amplifier from the vehicle.

Installing

Installation is performed in the reverse order of removal.

Note. Connect the lower air hose before installing the noise amplifier. Do not bend the air hose to the amplifier after installing.

Note. Make sure the noise amplifier is clipped in all three rubber buffers.

VACUUM PUMP, TFSI

Note. The vacuum pump is mechanically driven. The vacuum pump is installed on the engine on the left side.

Removing

Remove the engine cover.

Disconnect the connector -1- on the mass airflow sensor.

Scheme 159

Disconnect the ventilation hose -3-.

Remove the cover from the air filter housing.

Disconnect the air guide at the clamp -2-.

Move the air guide to the side.

Remove the vacuum hose form the vacuum pump.

Remove the screws on the vacuum pump sealing flange.

Remove the vacuum pump from the vehicle.

Installing

Note. Replace the seal. Make sure the seal is correctly installed.

Position the vacuum pump tappet so it engages in the groove on the camshaft when vacuum pump is installed.

Insert the vacuum pump.

Install and tighten all the bolts on the vacuum pump sealing flange to 9 Nm.

Connect the vacuum hose to the vacuum pump.

Install the air guide.

Secure the air guide with the clamp -2-.

Install the cover on the air filter housing.

Install the ventilation hose -3-.

Connect the connector -1- to the mass airflow sensor.

Install the engine cover.

VACUUM PUMP, TT RS

The vacuum pump is installed on the engine on the left side.

Removing

Remove the engine cover -1-.

Remove bolts -arrows- and remove the air guide.

Remove the bolts -arrows- and remove the air filter housing.

The coolant pipe is routed in front of the vacuum pump.

Remove the coolant pipe. Refer to [For engine(s) CETA, CCTA] Cooling System or to [For engine(s) CDMA] Cooling System or to [For engine(s) CBRA] Cooling System or to [For engine(s) BPY] Cooling System .

Pay attention to the following when working on the cooling system

Remove the vacuum hose -2- carefully. Replace the vacuum hose if damaged.

Scheme 160

Remove screws -1-.

Remove the vacuum pump while pushing the coolant hoses slightly to the side.

Installing

Note. Replace the seal.

Make sure the seal is correctly installed.

Position the vacuum pump tappet so it engages in the groove on the shaft in the engine when vacuum pump is installed.

Insert the vacuum pump.

Install and tighten all the bolts -1- on the vacuum pump sealing flange to 9 Nm.

Install the vacuum hose -2- onto the vacuum pump connection.

Note. Push the vacuum hose all the way onto the vacuum pump.

Install the coolant pipe. Refer to [For engine(s) CETA, CCTA] Cooling System or to [For engine(s) CDMA] Cooling System or to [For engine(s) CBRA] Cooling System or to [For engine(s) BPY] Cooling System .

Install the air filter housing and tighten the bolts -arrows-.

Install the air guide and tighten the bolts -arrows-.

Install the engine cover.

CHECK VALVE, TT RS

The check valve is installed in front of the brake booster.

Removing

Remove the engine cover -1-.

Remove the vacuum hoses from the check valve.

Installing

Make sure the check valve is installed correctly.

Note. The check valve must allow air to flow in the direction of the arrow. Valve must remain closed in opposite direction. The check valve is open in direction of the brake booster.

Install the vacuum hoses on the connections on the check valve.

Note. Moisten the connections on the check valve with water to make it easier to install the vacuum hoses.

Install the engine cover.

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 161

Scheme 162

Scheme 163

Scheme 164

Scheme 165

Scheme 166

Scheme 167

Scheme 168

1. Vehicle Diagnostic, Test And Information System Vas 5051
2. Brake Filler/Bleeder Unit Suction Adapter V.A.G 1869/4
3. Assembly Tool T10146
4. Torque Wrench V.A.G 1331
5. Brake Filler/Bleeder Unit Vas 5234 Or
6. Brake Filler/Bleeder Unit V.A.G 1869
7. Brake Pressure Gauge 0-250 Bar V.A.G 1310A
8. Brake Pedal Actuator V.A.G 1869/2
9. Disassembly Wedge 3409
10. Piston Resetting Tool T10145
11. Assembly Device For Protective Cap T10146/2
12. Resetting And Extracting Tool T10165

See also:
• DAMPER ON FRONT BRAKE CALIPER ASSEMBLY OVERVIEW
• BRAKE BOOSTER VACUUM SENSOR, WITH OPTIMIZED HYDRAULIC BRAKE VACUUM (OHBV) BOOSTING
• BRAKE PEDAL AND BRAKE BOOSTER, SEPARATING
• ABS/ESP MARK 60 BRAKE SYSTEM COMPONENT AND INSTALLATION LOCATION OVERVIEW => List Item:13
• Removal and Installation
• BRAKE LIGHT SWITCH
• BRAKE LAMP SWITCH, TT RS
• [For engine(s) CBRA] Cooling System
• [For engine(s) BPY] Cooling System
• Pre-Bleed Brake Caliper
• FRONT BRAKE CALIPER PISTON, FN3
• REAR BRAKE CALIPER PISTON
• BRAKE BOOSTER
• BRAKE BOOSTER, TT RS
• NOISE AMPLIFIER, TFSI
• BRAKE MASTER CYLINDER
• BRAKE MASTER CYLINDER, TT RS
• BRAKE FLUID RESERVOIR
• CHECK VALVE, TT RS
• BRAKE SYSTEM BLEEDING