Front brakes FS-III
- 1 - Phillips screw
- 2 - brake disc. Replace only complete on the entire axle. To remove, you must first disconnect the caliper.
- 3 - brake pads. All 4 pads of one axle must be replaced.
- 4 - support
- 5 - guide pin, 30 Nm
- 6 - cover
- 7 - sealing ring. Be sure to replace.
- 8 - brake hose. No need to unscrew to replace pads.
- 9 - hollow bolt, 35 Nm
- 10 - shield
- 11 - bolt, 7 Nm
- 12 - wheel bearing housing
- 13 - hexagon socket screw, 8 Nm
- 14 - ABS speed sensor. Before installation, clean the intake hole and lubricate with AUDIG000650 grease
- 15 - wheel bearing
- 16 - retaining ring
- 17 - hub with rotor. Note: All screws located on the outside are coated with an anti-corrosion coating. Therefore, only original spare mounting bolts should be used.
Front brake mechanism. Caliper FN-3
- 1 - Phillips screw
- 2 - brake disc. Replace only as a complete set on the axle. To remove, you must first disconnect the caliper.
- 3 - brake pads. The outer brake pad on the reverse side has a glued film. After installing the pad, the film must be removed. Replace only complete on the entire axle.
Note: Before installing new pads, clean the calipers thoroughly to remove dirt (degrease). When doing this, pay particular attention to removing film residues on the adjacent surfaces of the outer pads.
- 4 - stopper. Insert into both holes of the caliper body.
- 5 - guide. Replace damaged covers. The repair kit includes a cushion with lubrication. It should be used to lubricate the guide pins.
- 6 - caliper body
- 7 - guide pin, 30 Nm
- 8 - cover
- 9 - sealing ring. Be sure to replace.
- 10 - brake hose. No need to unscrew to replace pads.
- 11 - hollow bolt, 35 Nm
- 12 - bolt with ribs, 125 Nm. Before installation, clean the mating surface and threads.
- 13 - bolt, 7 Nm
- 14 - shield
- 15 - wheel bearing housing
- 16 - hexagon socket screw, 8 Nm
- 17 - ABS speed sensor. Before installation, clean the intake hole and lubricate with AUDIG000650 grease
- 18 - wheel bearing
- 19 - retaining ring
- 20 - hub with rotor. Note: All screws located on the outside are coated with an anti-corrosion coating. Therefore, only original spare mounting bolts should be used.
Caliper FS-III
Warning: All bolts located on the outside have an anti-corrosion coating. Therefore, only original spare bolts should be used.
Warning: There are two different versions of the front wheel brake. Therefore, using the illustration, find out which version is installed on your car.
Withdrawal
Warning: Brake pads are subject to the control of the General Regulations for Authorization to Service (ABE). In addition, they are designed by the manufacturer to be installed on a specific car model. Therefore, it is recommended to use only brake pads approved by the manufacturer.
1. Mark with paint the position of the corresponding front wheel relative to the hub. This will allow the assembly to install the balanced wheel in its original position. Loosen the wheel bolts with the vehicle on the ground. Raise the front of the car, put it on stands and remove the front wheel.
Warning: If the brake pads are to be reinstalled, they must be marked before being removed. It is not allowed to change brake pads from outside to inside and vice versa or from left to right wheel. Be sure to replace all front wheel pads at the same time, even if only one of them has reached the wear limit.
2. Remove covers -1- from both guide pins. Unscrew both guide pins with a socket wrench.
3. Secure the caliper with wire to the suspension.
Warning: Do not lower the caliper as this may cause the brake hose to pull out.
4. Take out the brake pads.
Installation
Warning: Do not press the brake pedal with the pads removed. Otherwise, the piston will be squeezed out of the housing. In this case, remove the caliper in the kit and insert it into place in the service station.
5. Clean the guide surfaces and the chock seats in the shaft with a rag and alcohol. Do not use solvents containing mineral oils or sharp-edged tools for this.
Warning: Only use alcohol to clean the brake.
6. Before installing the pads, check the brake disc by feeling it with your fingers. If there are scuffs, the brake disc can be machined (service station work), if it is still thick enough.
7. Measure the disc thickness, while referring to subsection Checking the thickness of the brake disc.
8. Check for cracks in the piston boot. If there is damage, replace the dust boot immediately, as the penetrating dirt quickly leads to loss of tightness of the caliper. The caliper for this must understand (service station work).
Warning: If the brake pads are heavily worn, check the piston for ease of movement. To do this, insert a wooden block into the caliper and ask the assistant to slowly press the brake pedal. The piston should move easily in both directions. To check, you need to put another caliper. Pay attention not to completely squeeze out the piston. If the piston stroke is heavy, the caliper must be repaired (service station work).
9. Push the piston back using the tool. This can also be done with a hardwood block (hammer handle). When doing this, make sure that the piston is not warped and that the surfaces of the piston and boot are not damaged.
Warning: When the piston is depressed, brake fluid is squeezed into the reservoir. Monitor the flow of liquid into the reservoir. Remove excess if necessary.
Warning: Use a plastic bottle designed for this purpose only to suck out the brake fluid. Do not use a drinking bottle for this! Brake fluid is poisonous. In no case should it be sucked off by mouth through a hose. Use a siphon for this purpose. After replacing the brake pads, the fluid level in the reservoir must not exceed the MAX mark on the reservoir, as the brake fluid expands when heated. Escaping fluid flows down the brake cylinder, destroying the coating and leading to corrosion.
10. Insert the brake pads into the caliper guides.
11. Install the caliper from the bottom first (arrow illustration).
Warning: Pin (arrow) the caliper must be behind the guide of the wheel bearing housing.
12. Secure the caliper with both guide pins to the wheel bearing housing with a torque of 30 Nm.
13. Install both finger covers.
14. Install both front wheels so that the marks made during removal match. Tighten the wheel bolts. Lower the vehicle onto the wheels and tighten the wheel bolts crosswise to 120 Nm.
Warning: Press the brake pedal hard several times until you feel a distinct resistance on the pedal. Thus, the pads will lie against the brake disc and take their place.
15. Check the brake fluid level in the reservoir. Top up to the MAX mark if necessary.
16. Carefully let the new brake pads run in. To do this, brake the car several times from a speed of 80 to 40 km / h, lightly pressing the pedal. Let the brake cool down between braking.
Warning: After installing new pads, they must be run in. To do this, when driving for a distance of the first 200 km, you should not unnecessarily strongly slow down the car.
Warning: In some regions, brake pads must be disposed of as special material. Local authorities must inform drivers of permitted disposal sites.
Warning: Do a Reliability Check:
- Are the brake hoses securely tightened?
- Is the brake hose secured in the holder?
- Are the bleed fittings tight?
- Is there enough brake fluid in the reservoir?
- With the engine running, check the system for leaks. To do this, press the brake pedal with a force of 200–300 N (20–30 kg) within 10 s. The pedal must not move. Check all connections for tightness.
Caliper FN-3
Withdrawal
Warning: Brake pads are subject to the control of the General Regulations for Authorization to Service (ABE). In addition, they are designed by the manufacturer to be installed on a specific car model. Therefore, it is recommended to use only brake pads approved by the manufacturer.
17. Mark with paint the position of the corresponding front wheel relative to the hub. This will allow the assembly to install the balanced wheel in its original position. Loosen the wheel bolts with the vehicle on the ground. Raise the front of the car, put it on stands and remove the front wheel.
Warning: If the brake pads are to be reinstalled, they must be marked before being removed. It is not allowed to change brake pads from outside to inside and vice versa or from left to right wheel. Be sure to replace all front wheel pads at the same time, even if only one of them has reached the wear limit.
18. Remove covers -1- from both guide pins. Unscrew both guide pins with an Allen key.
19. Pry with a screwdriver and remove the brake pad retainers.
20. Unscrew both guide pins from the caliper.
21. Remove the caliper and tie it with wire to the body.
Warning: Do not lower the caliper as this may cause the brake hose to pull out.
22. Remove the outer block from the brake shield.
23. Take out the inner pad (with lock) from the piston.
Installation
Warning: Do not press the brake pedal with the pads removed. Otherwise, the piston will be squeezed out of the body. In this case, remove the caliper in the kit and insert it into place in the service station.
24. Clean the guide surfaces and the chock seats in the shaft with a rag and alcohol. Do not use solvents containing mineral oils or sharp-edged tools for this.
Warning: Only use alcohol to clean the brake.
25. Before installing the pads, check the brake disc by feeling it with your fingers. If there are scuffs, the brake disc can be machined (service station work), if it is still thick enough.
26. Measure the disc thickness, while referring to subsection Checking the thickness of the brake disc.
27. Check for cracks in the piston boot. If there is damage, replace the dust boot immediately, as the penetrating dirt quickly leads to loss of tightness of the caliper. The caliper for this must understand (service station work).
Warning: If the brake pads are heavily worn, check the piston for ease of movement. To do this, insert a wooden block into the caliper and ask the assistant to slowly press the brake pedal. The piston should move easily in both directions. To check, you need to put another caliper. Pay attention not to completely squeeze out the piston. If the piston stroke is heavy, the caliper must be repaired (service station work).
28. Push in the piston using the tool. This can also be done with a hardwood block (hammer handle). When doing this, make sure that the piston is not warped and that the surfaces of the piston and boot are not damaged.
Warning: When the piston is pressed, brake fluid is squeezed into the reservoir. Monitor the flow of liquid into the reservoir. Remove excess if necessary.
Warning: Use a plastic bottle designed for this purpose only to suck out the brake fluid. Do not use a drinking bottle for this! Brake fluid is poisonous. In no case should it be sucked off by mouth through a hose. Use a siphon for this purpose. After replacing the brake pads, the fluid level in the reservoir must not exceed the MAX mark on the reservoir, as the brake fluid expands when heated. Escaping fluid flows down the brake cylinder, destroying the coating and leading to corrosion.
29. Insert inner brake pad (with lock) into the brake piston.
Warning: Internal brake pad (with lock) has an arrow, refer to the accompanying illustration. The arrow must point in the direction of rotation of the brake disc when the vehicle is moving forward. Incorrect installation (to the other side of the car) this may cause noise.
30. Install the outer brake shoe on the guide.
31. Remove the protective film from the back plate of the outer brake pad.
32. Install the caliper and secure it with both guide pins to the guide with a torque of 30 Nm.
33. Install both finger covers.
34. Insert the clamp -1- into the caliper.
Warning: After installing in both holes, the retainer must be pressed under the rail. If the outer shoe is not installed correctly, despite wear, it will not be installed, which leads to an increase in pedal travel.
35. Install both front wheels so that the marks made during removal match. Tighten the wheel bolts. Lower the vehicle onto the wheels and tighten the wheel bolts crosswise to 120 Nm.
Warning: Press the brake pedal hard several times until you feel a distinct resistance on the pedal. Thus, the pads will lie against the brake disc and take their place.
36. Check the brake fluid level in the reservoir. Top up to the MAX mark if necessary.
37. Carefully let the new brake pads run in. To do this, brake the car several times from a speed of 80 to 40 km / h, lightly pressing the pedal. Let the brake cool down between braking.
Warning: After installing new pads, they must be run in. To do this, when driving for a distance of the first 200 km, you should not unnecessarily strongly slow down the car.
Warning: In some regions, brake pads must be disposed of as special material. Local authorities must inform drivers of permitted disposal sites.
Warning: Do a Reliability Check:
- Are the brake hoses securely tightened?
- Is the brake hose secured in the holder?
- Are the bleed fittings tight?
- Is there enough brake fluid in the reservoir?
With the engine running, check the system for leaks. To do this, press the brake pedal with a force of 200–300 N (20–30 kg) within 10 s. The pedal must not move. Check all connections for tightness.
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