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

FRONT BRAKES, SERVICING

Read and observe general information before servicing.

Note. Use Brake Charger/Bleeder Unit VAS 5234 to extract brake fluid from brake fluid reservoir. Before removing a brake caliper or disconnecting a brake hose from a brake caliper, install the brake pedal loading device V.A.G 1869/2, to prevent the brake fluid reservoir from draining. When siphoning brake fluid, always use a bleeder bottle that is used exclusively for brake fluid. Make sure that brake fluid cannot leak out because it will damage components and the paint. Always use complete repair kit.

FRONT BRAKES, TT RS, SERVICING

1. Install complete repair set
2. After replacing brake pads, depress brake pedal several times firmly to properly seat brake pads in their normal operating position.

Scheme 85

1. Bleed Screw 10 Nm NOTE: Bleed the brake caliper at each bleed screw.
2. Bolt 200 Nm Remove when removing the brake caliper NOTE: Replace the bolts each time it is removed
3. Speed Sensor
4. Bolt 8 Nm For the speed sensor.
5. Brake Caliper NOTE: Do not hang on the brake hose after removing. Secure to the body with wire. Removing and Installing «FRONT BRAKE CALIPER, TT RS»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#mechanical-components-brake-system-roadster__front-brake-caliper-tt-rs) Replace «FRONT BRAKE CALIPER, TT RS»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#mechanical-components-brake-system-roadster__front-brake-caliper-tt-rs)
6. Brake Rotor Wear limit «FRONT BRAKE PADS, TT RS»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#mechanical-components-brake-system-roadster__front-brake-pads-tt-rs) NOTE: Remove brake caliper prior to removing Removing and Installing «FRONT BRAKE ROTOR TT RS»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#mechanical-components-brake-system-roadster__front-brake-rotor-tt-rs)
7. Bolt 4 Nm. For securing the brake rotor. NOTE: Use a new bolt after removing.
8. Brake Pads With a brake pad wear wire only in the left brake caliper. Wear limit «FRONT BRAKE PADS, TT RS»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#mechanical-components-brake-system-roadster__front-brake-pads-tt-rs) Removing and Installing «FRONT BRAKE PADS, TT RS»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#mechanical-components-brake-system-roadster__front-brake-pads-tt-rs) Before installing the brake pads, clean the pad guides and coat them grease. Peel off the adhesive film before installing the pads
9. Brake Pad Wear Wire Installed only in the left brake caliper.
10. Clip Make sure that it is installed in the correct position NOTE: Install the brake pad wear wire into the clip. Installed only in the left brake caliper.
11. Brake Pad Pin NOTE: Be careful not to scratch or damage the brake caliper when removing and installing it.
12. Bolt 18 Nm. For the bracket
13. Brake Hose 35 Nm. Install in the brake caliper. Install the in the bracket. Tightening specification 35 Nm, brake hose to the brake caliper for "TT RS" NOTE: seat properly in retainer Do not twist it when installing
14. Bracket For the brake hose and the brake pad wear wire.

REAR BRAKES, SERVICING

Note. To siphon off brake fluid from the brake fluid reservoir, use the Brake Charger/Bleeder Unit VAS 5234 or the Brake Charger/Bleeder Unit Adapter V.A.G 1869/4. Before removing a brake caliper or disconnecting a brake hose from a brake caliper, install the brake pedal loading device V.A.G 1869/2, to prevent the brake fluid reservoir from draining.

FRONT BRAKES ASSEMBLY OVERVIEW FRONT BRAKE SW, 17" FNR G57

1. Install complete repair set.
2. After replacing brake pads, depress brake pedal several times firmly to properly seat brake pads in their normal operating position.

Scheme 86

1. Brake Disc Must always be replaced together on both sides of vehicle. Remove brake caliper before removing. Coat contact surfaces between brake disc and wheel hub with Polycarbamide grease G 052 142 A2. Refer to «General Information»(/audi/tt/8j-2006-2010/remont/wheel-tire-system/#wheels-tires-wheel-alignment-roadster) . Allocation, dimensions, wear limits, refer to «TECHNICAL DATA»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#general-technical-data-brake-system-roadster) . Checking thickness, refer to Maintenance Booklet 808.
2. Retaining Spring Ensure installation position is correct.
3. Brake Caliper Housing Piston diameter, refer to «TECHNICAL DATA»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#general-technical-data-brake-system-roadster) . To replace brake pads, unfasten from brake carrier. Removing and installing, refer to «FRONT BRAKE CALIPER, 17" FNR G57»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#mechanical-components-brake-system-roadster__front-brake-caliper-17-fnr-g57) Servicing, refer to «FRONT BRAKE CALIPER SERVICING, FNRG57»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#hydraulic-components-brake-system-roadster__front-brake-caliper-servicing-fnrg57) . 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) .
4. Bushing Insert in brake caliper housing.
5. Guide Pins 30 Nm
6. Cap
7. Wear Indicator Wiring Bracket
8. Bolt Wiring bracket to brake caliper. 25 Nm
9. Cap
10. Bolt Brake line bracket to brake caliper. 15 Nm
11. Bracket for Brake Line Bolt to brake caliper housing. Hook in brake line.
12. Brake Line Installing brake caliper housing with «FRONT BRAKES ASSEMBLY OVERVIEW FRONT BRAKE SW, 17" FNR G57»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#mechanical-components-brake-system-roadster__front-brakes-assembly-overview-front-brake) . Hose must be installed free of twists. Brake line connection to brake caliper: 14 Nm. Brake line connection to brake hose: 14 Nm When connecting brake line with brake hose, counterhold at brake hose hex head.
13. Spring Clamp Holds brake line in bracket «FRONT BRAKES ASSEMBLY OVERVIEW FRONT BRAKE SW, 17" FNR G57»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#mechanical-components-brake-system-roadster__front-brakes-assembly-overview-front-brake) .
14. Brake pads With wear indicator (only on left side on inner pad). Pad thickness, wear limit, refer to «TECHNICAL DATA»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#general-technical-data-brake-system-roadster) . Removing and installing, refer to «FRONT BRAKE PADS, 17" FNR G57»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#mechanical-components-brake-system-roadster__front-brake-pads-17-fnr-g57) . NOTE: Before installing the brake pads, clean the pad guide surface and coat it with a film of grease. Must always be replaced together on both sides of vehicle. Checking thickness, refer to Maintenance Booklet 808. 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.
15. Brake Carrier
16. Bolt Brake carrier to wheel bearing housing. Always replace after removal. 200 Nm

FRONT BRAKES ASSEMBLY OVERVIEW, 16" FN3

1. Install complete repair set.
2. After replacing brake pads, depress brake pedal several times firmly to properly seat brake pads in their normal operating position.

Scheme 87

1. Wheel Bearing Unit with Integrated ABS Sensor Wheel Removing and installing, refer to «Removal and Installation»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-roadster) .
2. Wheel Speed Sensor Removing and installing, refer to «FRONT ABS WHEEL SPEED SENSOR»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#anti-lock-brake-system-roadster__front-abs-wheel-speed-sensor) .
3. Bolt 8 Nm
4. Cover Plate
5. Bolt 10 Nm
6. Brake Disc Allocation, dimensions, wear limits, refer to «TECHNICAL DATA»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#general-technical-data-brake-system-roadster) . Remove brake caliper housing, to remove. Do not use excessive force to separate the brake rotor from the wheel hub. If necessary, use rust penetrant, otherwise the brake rotors could be damaged. Must always be replaced together on both sides of vehicle.
7. Bolt Only loosen to remove brake disc. 4 Nm.
8. Brake Carrier Bolt to wheel bearing housing. 200 Nm If the protective caps are damaged, install repair kit; use included grease packet to grease the guide pins.
9. Brake Pads With wear indicator (only on left side on inner pad). Pad thickness, wear limit, refer to «TECHNICAL DATA»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#general-technical-data-brake-system-roadster) . Must always be replaced together on both sides of vehicle. NOTE: Before installing the brake pads, clean the pad guide surface and coat it with a film of grease. Removing and installing, refer to «FRONT BRAKE PADS, 16" FN3»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#mechanical-components-brake-system-roadster__front-brake-pads-16-fn3) . Checking brake pad thickness, refer to Maintenance Booklet 808. 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.
10. Retaining Spring Insert in both holes of brake caliper housing.
11. Brake Caliper Housing Piston diameter, refer to «TECHNICAL DATA»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#general-technical-data-brake-system-roadster) . To replace brake pads, unfasten from brake carrier. Removing and installing, refer to «FRONT BRAKE CALIPER, 16" FN3»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#mechanical-components-brake-system-roadster__front-brake-caliper-16-fn3) . Servicing, refer to «FRONT BRAKE CALIPER ASSEMBLY OVERVIEW, FN3»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#hydraulic-components-brake-system-roadster) . Brake line connection to brake caliper: 19 Nm. Brake line connection to brake hose: 12 Nm When connecting brake line with brake hose, counterhold at brake hose hex head. 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) .
12. Bracket
13. Bolt Bracket to brake caliper.
14. Cap
15. Guide Pins Brake caliper to brake carrier. 30 Nm
16. Bushing
17. Cap
18. Bolt Brake carrier to wheel bearing housing. Always replace after removal. 200 Nm

Scheme 88

Brake hose to the brake caliper for 16" FN-3 brakes, tightening specification: 35 Nm.

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

DAMPER ON FRONT BRAKE CALIPER ASSEMBLY OVERVIEW

Note. Not all models have the balance weight. This does not affect removing, installing and servicing the brake caliper.

Scheme 89

1. Dust Cap
2. Bolt Always replace. 10 Nm
3. Damper Removing and installing, refer to «DAMPER»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#mechanical-components-brake-system-roadster__damper) .
4. Washer
5. Brake Caliper

Scheme 90

1. Brake Disc Allocation, dimensions, wear limits, refer to «TECHNICAL DATA»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#general-technical-data-brake-system-roadster) . Do not use excessive force to separate the brake rotor from the wheel hub. If necessary, use rust penetrant, otherwise the brake rotors could be damaged. Remove brake caliper prior to removing. Must always be replaced together on both sides of vehicle.
2. Brake Caliper Do not disconnect brake hose when changing brake pads. Piston diameter, refer to «TECHNICAL DATA»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#general-technical-data-brake-system-roadster) . Removing and installing, refer to «REAR BRAKE CALIPER»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#mechanical-components-brake-system-roadster__rear-brake-caliper) . Servicing, refer to «REAR BRAKE CALIPER SERVICING»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#hydraulic-components-brake-system-roadster__rear-brake-caliper-servicing) . Parking brake must be adjusted after servicing or replacing, refer to «PARKING BRAKE, ADJUSTING»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#mechanical-components-brake-system-roadster__parking-brake-adjusting) .
3. Brake Line Do not disconnect brake hose and brake line when changing brake pads. Tightening specification, brake line, for all models: 14 Nm.
4. Brake Hose Do not disconnect brake hose when changing brake pads. Tightening specification, brake hose, for all models: 14 Nm.
5. Protective Cap
6. Bolt Remove to change pad. Always replace after removal. Brake caliper to brake carrier. Self-locking. When loosening and tightening, counter-hold at guide pin. 35 Nm NOTE: Replace the bolt each time it is removed.
7. Bleeder Screw 10 Nm
8. Cap
9. Parking Brake Resetting Spring
10. Nut Parking brake linkage to brake caliper. Must not be loosened.
11. Parking Brake Cable Removing and installing, refer to «PARKING BRAKE CABLE»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#mechanical-components-brake-system-roadster) .
12. Parking Brake Linkage
13. Brake Pad Securing Spring Always replace when pads are replaced.
14. Speed Sensor Wire
15. Brake Pads Must always be replaced together on both sides of vehicle. Wear limit, refer to «TECHNICAL DATA»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#general-technical-data-brake-system-roadster) . Removing and installing, refer to «REAR BRAKE PADS»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#mechanical-components-brake-system-roadster__rear-brake-pads) . Wear limit, TT RS, refer to «FRONT BRAKE PADS, TT RS»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#mechanical-components-brake-system-roadster__front-brake-pads-tt-rs) Before installing the brake pads, clean the pad guide surface and coat it with a film of grease. Removing and installing, refer to «REAR BRAKE PADS»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#mechanical-components-brake-system-roadster__rear-brake-pads) . Checking brake pad thickness, refer to Maintenance Booklet 808. Version. 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.
16. Bolt Brake carrier to wheel bearing housing. Always replace after removal. 90 Nm + 90° turn NOTE: Replace the bolt each time it is removed.
17. Brake Carrier Bolt to wheel bearing housing.

Scheme 91

1. Parking Brake Lever Supplied as replacement part assembled with relay rod, locking latch, push rod, push button, spring and locking segment. Removing and installing, refer to «PARKING BRAKE HANDLE»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#mechanical-components-brake-system-roadster__parking-brake-handle) . Switch for indicator lamp installed under parking brake lever.
2. Parking Brake Switch Removing and installing, refer to «PARKING BRAKE SWITCH»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#mechanical-components-brake-system-roadster) . For parking brake indicator light in instrument cluster.
3. Nut 15 Nm
4. Compensator With adjusting nut for adjusting parking brake cable.
5. Left and Right Parking Brake Cable

BRAKE PEDAL ASSEMBLY OVERVIEW

Scheme 92

1. Brake Booster Removing and installing, refer to «BRAKE BOOSTER»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#hydraulic-components-brake-system-roadster__brake-booster) .
2. Brake Light Switch to Brake Master Cylinder
3. Mounting Bracket With crash bar.
4. Bushing Lubricate mounting points with Polyurea grease G 052 142 A2 before installing.
5. Nut 25 Nm
6. Nut 25 Nm
7. Brake Pedal Removing and installing, refer to «BRAKE PEDAL»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#mechanical-components-brake-system-roadster__brake-pedal) . Disconnect from brake booster. 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) . Lubricate mounting points with Polyurea grease G 052 142 A2 before installing.
8. Cover
9. Bolt

FRONT BRAKE CALIPER PISTON, PRESSING BACK

Special tools and workshop equipment required

1. Piston resetting tool T10145

Note. Press brake piston back into caliper housing using resetting tool before inserting new brake pads. Before pressing back, extract brake fluid from reservoir with bleeder bottle so escaping fluid does not damage components.

Press the brake pistons back with the T10145.

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.

Scheme 93

Scheme 94

REAR BRAKE CALIPER PISTON, PRESSING BACK

Special tools and workshop equipment required

1. Resetting and extracting tool T10165

Note. Before pushing back the piston, siphon some of the brake fluid out of the brake fluid reservoir. To extract brake fluid from the brake fluid reservoir, use a bleeder bottle or a plastic bottle that only comes into contact with brake fluid.

Position T10165 on brake caliper housing piston.

Scheme 95

Install pistons at knurling wheel of T10165 by turning clockwise. Do not damage protective caps.

Note. If the piston is difficult to move, use a 13 mm open end wrench on the flats -arrow- provided for this purpose.

FASTENER TIGHTENING SPECIFICATIONS

1. 1 Always replace after removal.

PARKING BRAKE, ADJUSTING

Note. A new adjustment is necessary only after replacing brake cables, brake calipers or brake discs.

1. For parking brake cable zero adjustment, both rear wheels must run freely.
2. The parking brake lever must go below first catch by itself in zero position.
3. The adjusting nut on the compensator must be installed over the end of the relay rod.

Release parking brake.

Loosen cover in rear center console compartment with a hook and remove.

The parking brake cable -5- must be routed without tension.

Scheme 96

When adjusting parking brake, lever -1- may be raised a maximum of 2 degrees.

Install adjusting nut on compensator lever -2- until lever on brake caliper -4- can be raised from stop -3-.

With parking brake lever zero adjustment, distance -a- between lever on brake caliper -4- and stop -3- together must be at least 1 mm.

The maximum distance on a side must not exceed 4 mm.

Distance -a- to stop -3- on one side must be greater than 0 mm and must not exceed 4 mm.

Apply the parking brake 3 times and then release.

With parking brake released, check if both wheels can be turned freely. And the distance -a- at the calipers is maintained.

A light braking effect on the rear wheels must be noticeable in the first parking brake lever detent.

Correct the adjustment, if necessary, by adjusting the adjustment nut.

Note. Due to the automatic rear brake adjuster, there is no need to adjust the parking brake after making initial adjustment.

FRONT BRAKE PADS, 16" FN3

Special tools and workshop equipment required

1. Torque wrench V.A.G 1331
2. Torque wrench V.A.G 1410
3. Torque wrench V.A.G 1332
4. Brake pedal actuator V.A.G 1869/2
5. Piston resetting tool T10145

Removing

Raise vehicle.

Remove wheels.

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

Disconnect brake pad wear indicator connector -1- at left brake.

Scheme 97

Do not loosen bolt -2-.

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

Scheme 98

Remove brake caliper. Refer to FRONT BRAKE CALIPER, 16" FN3 .

Remove brake caliper and hang so brake line cannot be damaged by the weight of the brake caliper.

Note. Do not twist or kink brake hose line.

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

Clean brake caliper housing, in particular the adhesion surface for the brake pads. This must be free of adhesive residue and grease.

Note. Clean brake caliper with mineral spirits exclusively.

Installing

Before installing the brake pads, clean the pad guides and coat them grease.

Note. Push the brake pistons back using the T10145 before installing the brake pads. Refer to FRONT BRAKE CALIPER PISTON, PRESSING BACK .

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.

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

Insert brake pads in brake carrier, observe installation position

When brake pads are installed correctly, arrow on backing plate points down.

Scheme 99

1 - Right brake pad, piston side

2 - Left brake pad, piston side

Note. Brake pad with wear indicator sits at front in left brake caliper on inner brake pad.

Remove protective foil on backing plate of outer brake pad.

Scheme 100

Position brake caliper on brake carrier or brake disc.

Tighten brake caliper on brake carrier with both guide bolts. Note torque: 30 Nm.

Set retaining spring -arrow- into brake caliper housing.

Note. Make sure that brake hose is installed without being twisted or pulled.

Insert both cover caps on guide pins.

Install retaining spring in brake caliper housing.

Press in spring clip.

Connect wear indicator connector.

Press wear indicator connector in bracket and engage line.

Mounting wheels, refer to General Information .

Check brake fluid level, and fill if necessary.

Mounting wheels, refer to General Information .

FRONT BRAKE PADS, 17" FNR G57

Special tools and workshop equipment required

1. Torque wrench V.A.G 1331
2. Torque wrench V.A.G 1410
3. Torque wrench V.A.G 1332
4. Brake pedal actuator V.A.G 1869/2
5. Piston resetting tool T10145

Removing

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

Raise vehicle.

Remove wheels.

Mounting wheels, refer to General Information .

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

Scheme 101

Loosen bolt -1- (4 Nm) only to remove brake disc.

Disconnect brake pad wear indicator connector -1-.

Do not loosen bolt -2-.

Remove brake pad wear indicator connector from bracket and disengage cable.

Remove spring clip -arrow- from brake line bracket.

Scheme 102

Unhook brake line from retainer.

Remove bolt and remove brake line bracket.

Remove brake caliper. Refer to FRONT BRAKE CALIPER, 17" FNR G57 .

Remove brake caliper and hang so brake line cannot be damaged by the weight of the brake caliper.

Note. Do not twist or kink brake hose line.

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

Clean brake caliper housing, in particular the adhesion surface for the brake pads. This must be free of adhesive residue and grease.

Note. Clean brake caliper with mineral spirits exclusively.

Installing

Before installing the brake pads, clean the pad guide surface and coat it with a film of grease.

Note. Push the brake pistons back using the piston resetting tool T10145 before installing the brake pads. Refer to FRONT BRAKE CALIPER PISTON, PRESSING BACK .

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.

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

Note. Brake pad with wear indicator sits at front in left brake caliper on inner brake pad.

Set the brake pad with retaining spring and wear indicator into the brake caliper housing (piston).

Scheme 103

Set outer brake pad -2- onto the brake caliper.

Scheme 104

Wear indicator wire is on inside of left front brake pad -1-.

Position brake caliper with brake pads inserted on brake carrier or brake disc.

Tighten brake caliper housing to brake carrier using both guide pins. Note required torque: 30 Nm.

Note. Make sure that brake hose is installed without being twisted or pulled.

Install both protective caps.

Attach brake line bracket.

Install retaining spring in brake caliper housing.

Engage brake line in bracket.

Press in spring clip.

Connect wear indicator connector.

Press wear indicator connector in bracket and engage line.

Mounting wheels, refer to General Information .

Note. After hooking into both studs, the retaining spring must be pressed under the brake carrier. If improperly installed, the wear of the outer brake pad cannot be adjusted, thereby increasing brake pedal travel.

Note. Check brake caliper for ease of movement by moving it sideways.

Check brake fluid level, and fill if necessary.

FRONT BRAKE PADS, TT RS

Special tools and workshop equipment required

1. Piston resetting tool T10145

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

Removing

Raise the vehicle.

Remove the wheels.

Note. The brake pad wear wire is installed only in the left brake caliper.

Remove the brake pad wear wire -9- from the bracket.

Note. Do not loosen bolt -2-.

Disconnect the connector for the brake pad wear wire.

Push the brake pistons back into the brake caliper with pliers wit the brake pads installed.

Note. Do not scratch or damage the brake caliper.

Remove the brake pad wear wire -9- from the clamp -10-.

Remove the brake pad pin -11- from the brake caliper. Push the clamp -10- downward.

Remove the second brake pad pin -11- from the brake caliper.

Remove the brake pads from the brake caliper.

Clean brake caliper with mineral spirits exclusively.

Installing

Remove the adhesive film from the back of the brake pads.

Before installing the brake pads, clean the pad guides and coat them grease.

Push the brake pistons back using the piston resetting tool T10145 before installing the brake pads. Refer to FRONT BRAKE CALIPER PISTON, PRESSING BACK .

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.

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

Insert brake pads in brake caliper.

Note. Make sure the brake pads are installed correctly. The brake pads with the brake pad wear wire are only in the left brake caliper. The brake pad wear wire is in both brake pads in the left brake caliper.

Install a brake pad pin -11- from the inside to the outside through the brake caliper and brake pads.

Install the spring -10- under the pin -11-.

Push a second pin from the outside toward the inside through the brake caliper and the brake pads. Push the spring -10- downward.

Install the brake pad wear wire -9- into the spring -10-.

Connect the brake pad wear wire.

Install the brake pad wear wire into the bracket.

Mounting wheels Wheels, Tires, Wheel Alignment

Lower vehicle.

Check brake fluid level, and fill if necessary.

FRONT BRAKE CALIPER, 16" FN3

Special tools and workshop equipment required

1. Brake pedal actuator V.A.G 1869/2
2. Piston resetting tool T10145

Removing

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

Scheme 105

Note. By doing this, the valves in the brake master cylinder are closed and the brake fluid reservoir does not run empty.

Connect the hose of a bleeder bottle to the bleeder screw of the removed brake caliper.

Open bleeder screw.

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

Close the bleed screws.

Remove brake hose from brake caliper.

Remove cover caps on guide pins -arrows-.

Scheme 106

Remove guide pins -arrows-.

Scheme 107

Pull both guide pins out of brake caliper and bushings.

Remove brake pads. Refer to FRONT BRAKE PADS, 16" FN3 .

Installing

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

Remove V.A.G 1869/2.

Note. Push the brake pistons back using the T10145 before installing the brake pads. Refer to FRONT BRAKE CALIPER PISTON, PRESSING BACK .

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.

Install brake pads. Refer to FRONT BRAKE PADS, 16" FN3 .

Tighten brake caliper on brake carrier with both guide bolts. Note torque: 30 Nm

Connect the brake line in the brake caliper.

Brake hose in the brake caliper for 16" FN-3 brakes, tightening specification: 35 Nm.

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

Brake system, bleeding, refer to BRAKE SYSTEM BLEEDING .

Mounting wheels, refer to General Information .

FRONT BRAKE CALIPER, 17" FNR G57

Special tools and workshop equipment required

1. Brake pedal actuator V.A.G 1869/2
2. Piston resetting tool T10145

Removing

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

Note. By doing this, the valves in the brake master cylinder are closed and the brake fluid reservoir does not run empty.

Connect the hose of a bleeder bottle to the bleeder screw of the removed brake caliper.

Open bleeder screw.

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

Close the bleed screws.

Remove brake hose from brake caliper.

Remove cover caps on guide pins -arrows-.

Remove guide pins -arrows-.

Pull both guide pins out of brake caliper and bushings.

Remove brake pads FRONT BRAKE PADS, 17" FNR G57 .

Installing

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

Remove V.A.G 1869/2.

Note. Push the brake pistons back using the T10145 before installing the brake pads. Refer to FRONT BRAKE CALIPER PISTON, PRESSING BACK .

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.

Install brake pads. Refer to FRONT BRAKE PADS, 17" FNR G57 .

Slide both guide pins through bushings into brake caliper.

Tighten brake caliper housing to brake carrier using both guide pins. Note required torque: 30 Nm.

Connect the brake line to the brake caliper.

Brake hose in the brake caliper for 17" FNR- G57 brakes, tightening specification: 14 Nm.

Brake system, bleeding, refer to BRAKE SYSTEM BLEEDING .

Note. Check brake caliper for ease of movement by moving it sideways. Mounting wheels, refer to General Information .

Lower vehicle.

FRONT BRAKE CALIPER, TT RS

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

Removing

Raise the vehicle.

Remove the wheels.

Note. The brake pad wear wire is installed only in the left brake caliper.

Insert Brake Pedal Actuator V.A.G 1869/2 between brake pedal and driver's seat by pressing brake pedal down at least 60 mm.

Note. By doing this, the valves in the brake master cylinder are closed and the brake fluid reservoir does not run empty.

Connect the hose of a bleeder bottle to the bleeder screw of the removed brake caliper.

Open bleeder screw.

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

Close the bleed screws.

Remove brake hose from brake caliper.

Remove brake pads FRONT BRAKE PADS, TT RS

Remove the brake hose -13- from the brake caliper.

Remove bolts -2-. Hold the brake caliper tight when doing this.

Remove the brake caliper.

Installing

Note. Replace the bolts -2-.

Remove brake pedal loading device V.A.G 1869/2.

Insert the brake caliper.

Tighten the brake caliper with the new bolts -2-.200 Nm.

Push the brake pistons back using the piston resetting tool T10145 before installing the brake pads. Refer to FRONT BRAKE CALIPER PISTON, PRESSING BACK .

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.

Install brake pads FRONT BRAKE PADS, TT RS .

Install the brake hose -13- in the brake caliper and tighten.

Tightening specification 35 Nm, brake hose to the brake caliper for "TT RS"

Bleed the brake system at all bleed screws.

Mounting wheels Wheels, Tires, Wheel Alignment

Lower vehicle.

Check brake fluid level, and fill if necessary.

FRONT BRAKE ROTOR TT RS

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

Removing

Raise the vehicle.

Remove the wheels.

Note. The brake pad wear wire is installed only in the left brake caliper.

Remove the brake caliper. Refer to FRONT BRAKE CALIPER, TT RS .

Note. Do not let the brake caliper hang on the brake hose. Secure to the body with wire.

Remove bolt -7-.

Remove the brake rotor from the wheel hub.

Note. Do not tilt the brake rotor when removing it.

Installing

Note. Replace the bolt -7-.

Clean the wheel hub and the brake rotor surfaces.

Place the brake disc on the hub.

Note. Do not tilt the brake rotor when installing it.

Tighten the new bolt -7- for the brake rotor to 4 Nm.

Install the brake caliper. Refer to FRONT BRAKE CALIPER, TT RS .

Mounting wheels Wheels, Tires, Wheel Alignment

Lower vehicle.

Check brake fluid level, and fill if necessary.

DAMPER

Removing

Raise vehicle.

Remove front wheels.

Remove the dust cap.

Remove the screw -2-.

Remove the balance weight -3- and washer -4- from the brake caliper.

Installing

Clean the brake caliper around the balance weight.

Install the washer -4- and balance weight -3- in the brake caliper.

Install a new screw -2- and tighten it to 10 Nm.

Install the dust cap -1-.

Mounting wheels, refer to General Information .

REAR BRAKE PADS

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

Special tools and workshop equipment required

1. Torque wrench V.A.G 1331
2. Piston resetting tool T10145

Removing

Raise vehicle.

Remove wheels.

Note. Do not loosen parking brake cable from brake caliper.

Remove brake caliper housing while counter holding at guide pins.

Scheme 108

Remove brake caliper housing from brake disc.

Hang brake caliper housing with wire so brake hose is not damaged by weight of brake caliper.

Remove brake pads and pad retaining springs from brake carrier -arrows-.

Scheme 109

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

Clean brake caliper housing, in particular the adhesion surface for the brake pads. This must be free of adhesive residue and grease.

Note. Clean brake caliper with mineral spirits exclusively.

Installing

Before installing the brake pads, clean the pad guide surface and coat it with a film of grease.

Note. Push the brake pistons back using the T10145 before installing the brake pads. Refer to FRONT BRAKE CALIPER PISTON, PRESSING BACK .

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.

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

Insert brake pad retaining springs -arrows- and brake pads into brake carrier.

Remove protective foil on backing plate of brake pad.

Note. Position brake caliper on brake carrier or brake disc.

Secure brake caliper housing using new self-locking bolts. Observe torque: 35 Nm.

Note. The repair kit includes four self-locking hex bolts which must be installed in all cases.

Mounting wheels, refer to General Information .

Check brake fluid level, and fill if necessary.

REAR BRAKE CALIPER

Special tools and workshop equipment required

1. Torque wrench V.A.G 1331
2. Brake pedal actuator V.A.G 1869/2
3. Piston resetting tool T10145

Removing

Raise vehicle.

Remove wheels.

Note. Only loosen parking brake cable for complete removal of brake caliper. Refer to PARKING BRAKE CABLE, LOOSENING FROM BRAKE CALIPER AND ENGAGING .

Remove brake pads. Refer to REAR BRAKE PADS .

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

Remove brake caliper housing while counter holding at guide pins.

Remove brake caliper housing from brake disc.

Hang brake caliper housing with wire so brake hose is not damaged by weight of brake caliper.

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

Note. By doing this, the valves in the brake master cylinder are closed and the brake fluid reservoir does not run empty.

Connect the hose of a bleeder bottle to the bleeder screw of the removed rear brake caliper, as well as the front brake caliper on the same side of the vehicle.

Open both bleeder screws.

Close front bleeder screw.

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

Remove brake hose from brake caliper.

Installing

Note. Push the brake pistons back using the T10145 before installing the brake pads. Refer to FRONT BRAKE CALIPER PISTON, PRESSING BACK .

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.

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

Install brake pads. Refer to REAR BRAKE PADS .

Secure brake caliper housing using new self-locking bolts. Observe torque: 35 Nm

Install the brake hose in the brake caliper.

Tightening specification, brake hose to brake caliper: 14 Nm

Note. Make sure that brake hose is installed without being twisted or pulled.

After installing a serviced or new brake caliper, parking brake must be adjusted. Refer to PARKING BRAKE, ADJUSTING . After adjusting parking brake, actuate the brake pedal first.

Bleed the brake system. Refer to BRAKE SYSTEM BLEEDING .

PARKING BRAKE HANDLE

Removing

Release parking brake.

Remove center console trim. Refer to Removal and Installation .

Turn adjusting nut on compensator -4- until left and right of parking brake cable -5- can be disengaged from compensator.

Remove parking brake switch -2-. Refer to PARKING BRAKE SWITCH .

Remove nuts -3-.

Remove parking brake lever from vehicle.

Installing

Installation is performed in reverse sequence.

Install parking brake switch. Refer to PARKING BRAKE SWITCH .

Tension parking brake cable with compensator adjusting nut -4-.

Note. After installing brake cable, parking brake must be adjusted. Refer to PARKING BRAKE, ADJUSTING .

Scheme 110

1. Release Knob
2. Trim, One-Piece Installation depends on equipment version.
3. Left Trim Installation depends on equipment version.
4. Parking Brake Switch For parking brake indicator light in instrument cluster.
5. Right Trim Installation depends on equipment version.
6. Cap
7. Bolt 0.7 Nm

Removing

Remove center console trim. Refer to Removal and Installation .

Remove release knob -1-.

Note. Note different versions of parking brake trim.

Release one-piece parking brake trim -2- and pull forward.

Release handle on two-piece trim and pull forward.

Remove two-piece parking brake trim.

Unclip parking brake switch -4-.

Disconnect electrical connector.

Installing

Installation is performed in the reverse order of removal.

Note. After installing parking brake switch, parking brake must not be adjusted.

Scheme 111

1. Lower Right Guide Tube for Right Parking Brake Cable
2. Clip for Lower Right Guide Tube
3. Nut for Lower Right Clip Do not loosen to remove parking brake cable and guide tube. 12 Nm
4. Left and Right Bolt 4 Nm
5. Brake Cable Bracket to Left and Right Axle Beam Remove underbody protection, depending on model.
6. Left and Right Parking Brake Cable
7. Left and Right Rubber Grommets
8. Left and Right Parking Brake Cable
9. Left and Right Parking Brake Cable Bracket
10. Clip for Lower Left Guide Tube
11. Lower Left Guide Tube

Removing

Release parking brake.

Loosen cover in rear center console compartment with a hook and remove.

Remove the parking brake cable adjusting nut far enough so left and right parking brake cable -3- can be disengaged from compensator -4-.

Scheme 112

Raise vehicle.

Loosen parking brake cable from left and right brake caliper. Refer to PARKING BRAKE CABLE, LOOSENING FROM BRAKE CALIPER AND ENGAGING .

Loosen right bolt from right axle beam and remove bracket with parking brake cable.

Disengage right parking brake cable from bracket.

Unclip right guide tube PARKING BRAKE, ADJUSTING from bracket PARKING BRAKE CABLE GUIDE TUBE , do not loosen nut PARKING BRAKE CABLE .

Carefully remove right parking brake cable from right guide tube.

Loosen left bolt from left axle beam and remove bracket with parking brake cable.

Disengage left parking brake cable from bracket.

Unclip left guide tube PARKING BRAKE CABLE from left bracket PARKING BRAKE CABLE .

Carefully remove left parking brake cable from left guide tube.

Installing

Note. The parking brake cable must not be tensioned or pulled.

Installation is performed in the reverse order of removal.

Carefully place left and right parking brake cables through respective guide tube in vehicle interior.

Engage parking brake cable in left and right brake caliper. Refer to PARKING BRAKE CABLE, LOOSENING FROM BRAKE CALIPER AND ENGAGING .

Lower vehicle.

Remove left and right parking brake cable -3- upward out of respective guide tube -2-.

Engage left and right parking brake cable -3- in compensator -4-.

Tension parking brake cable with compensator adjusting nut -4-.

Note. After installing brake cable, parking brake must be adjusted. Refer to PARKING BRAKE, ADJUSTING .

PARKING BRAKE CABLE GUIDE TUBE

Removing

Remove parking brake cable. Refer to PARKING BRAKE CABLE .

Unclip guide tubes from vehicle floor.

Remove guide tubes -2- from below from vehicle shaft.

When doing so, ensure rubber grommets -1- are not damaged.

Installing

Slide guide tubes -2- from below through vehicle shaft into vehicle interior.

When doing so, ensure rubber grommets -1- are not damaged.

Clip guide tubes into mounts on vehicle floor.

PARKING BRAKE CABLE, LOOSENING FROM BRAKE CALIPER AND ENGAGING

Removing

Press brake lever -2- in direction of arrow and unhook parking brake cable -3-.

Scheme 113

Press retaining tabs -1- together while removing parking brake cable from guide.

Installing

Insert parking brake cable through guide.

Press retaining tabs -1- together and engage. Make sure that both retaining tabs are engaged.

Press brake lever -2- in direction of arrow and engage parking brake cable -3-.

BRAKE PEDAL

Removing

Remove the driver side storage tray. Refer to Removal and Installation .

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

Remove nut -5-.

Remove hex bolt -9- from brake pedal and bushing.

Installing

Installation is performed in the reverse order of removal.

Slide hex bolt -9- through brake pedal and bushing.

Use new nut -5- and tighten. Note torque: 25 Nm

Note. Lubricate mounting points with Polyurea grease G 052 142 A2 before installing.

Clip brake pedal to brake booster push rod ball head.

Scheme 114

Hold ball head of push rod in front of mounting and push brake pedal in direction of brake booster, so the ball head locates audibly. Refer to BRAKE PEDAL AND BRAKE BOOSTER, SEPARATING .

BRAKE PEDAL AND BRAKE BOOSTER, SEPARATING

Special tools and workshop equipment required

1. Release tool T40024

Separating

Remove the driver side storage tray. Refer to Removal and Installation .

Disconnect the brake pedal from the brake booster using T40024.

Scheme 115

Guide in the T40024 and press together, while pulling brake pedal toward the driver seat. (The brake pedal will thereby be pulled off the ball head of the push rod.)

Installing

Clip brake pedal to brake booster push rod ball head.

Hold ball head of push rod in front of mounting and push brake pedal in direction of brake booster, so the ball head locates audibly.

Install the driver side storage tray. Refer to Removal and Installation

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 116

Scheme 117

1. Torque wrench V.A.G 1332
2. Resetting and extracting tool T10165
3. Release tool T40024

Scheme 118

Special tools and workshop equipment required

1. Torque wrench V.A.G 1331
2. Torque wrench V.A.G 1410
3. Brake pedal actuator V.A.G 1869/2
4. Piston resetting tool T10145

See also:
• General Information
• TECHNICAL DATA
• FRONT BRAKE CALIPER SERVICING, FNRG57
• Removal and Installation
• FRONT ABS WHEEL SPEED SENSOR
• FRONT BRAKE CALIPER ASSEMBLY OVERVIEW, FN3
• REAR BRAKE CALIPER SERVICING
• BRAKE BOOSTER
• General Information
• BRAKE SYSTEM BLEEDING
• Removal and Installation
• FRONT BRAKE CALIPER, TT RS
• FRONT BRAKE PADS, TT RS
• FRONT BRAKE ROTOR TT RS
• FRONT BRAKE CALIPER, 17" FNR G57
• DAMPER ON FRONT BRAKE CALIPER ASSEMBLY OVERVIEW
• FRONT BRAKES ASSEMBLY OVERVIEW FRONT BRAKE SW, 17" FNR G57
• FRONT BRAKE PADS, 17" FNR G57
• FRONT BRAKE PADS, 16" FN3
• FRONT BRAKE CALIPER, 16" FN3
• DAMPER
• REAR BRAKE CALIPER
• PARKING BRAKE, ADJUSTING
• PARKING BRAKE CABLE
• REAR BRAKE PADS
• PARKING BRAKE HANDLE
• BRAKE PEDAL
• BRAKE PEDAL AND BRAKE BOOSTER, SEPARATING
• FRONT BRAKE CALIPER PISTON, PRESSING BACK
• PARKING BRAKE CABLE, LOOSENING FROM BRAKE CALIPER AND ENGAGING
• PARKING BRAKE CABLE GUIDE TUBE