Brake pedal — removal and installation (Audi A4 B5)

Table of contents: Removal ↓ Installation ↓

Removal

1. Disconnect the ground wire from the battery.

2. Remove the brake master cylinder as described paragraph 10.

3. Remove the brake booster.

4. Disconnect the hydraulic pipe from the rear of the clutch master cylinder as described in chapter 6. Lay out rags to collect spilled liquid.

5. On left-hand drive models, remove the screw securing the pedal bracket, which is located on the firewall at the rear of the engine compartment, behind the power steering mounts.

6. Remove the panels under the fascia to access the base of the steering column.

7. Turn the steering wheel to set the wheels in the straight-ahead position. Fix the wheel in this position for the duration of the procedure.

8. Loosen the nut of the through bolt securing the hinge at the base of the steering column to the steering gear. Turn the bolt half a turn and remove it from the hinge clamp.

9. Tie the lower section of the steering column to the upper section with wire to prevent them from separating when the column is removed. Warning: Do not allow the steering column to separate when removed. Do not move the wheels before installing the steering column, otherwise the position of the air bag contact group will be disturbed and the ABS system will not function properly.

10. Pull the steering column joint off the steering gear shaft and move the joint to the side.

11. Release the brake light contact sensor from the mounting bracket and set it aside. If provided, disconnect the vacuum control valves from the brackets above the pedal block and set them aside.

12. On petrol models, disconnect the cable from the accelerator pedal as described in chapter 4A.

13. Unscrew the nut securing the pedal assembly to the engine shield and remove the assembly from under the front panel. Try not to damage the immobilizer control unit.

14. On right-hand drive models, remove the mounting bolt and the power steering control lever to the left of the clutch pedal. Remove the brake pedal from the pedal assembly.

15. On left-hand drive models, release the clips and remove the pedal shaft. Remove the brake pedal from the pedal assembly.

16. Inspect the removed components, replace any worn or damaged ones.

Installation

5. Apply a layer of multi-purpose plastic lubricant to the rubbing surfaces. Then the assembly operation is performed in reverse order. Please note the following:

a) Do not remove the wire that connects the two sections of the steering column together until the joint is installed on the steering gear shaft.
b) Do not tighten the pedal bracket mounting nut until the brake booster is installed.
c) Tighten all fasteners to the specified torques.
d) Install the accelerator cable as described in chapter 4A.
d) Install the brake booster as described in paragraph 12.
e) Install the brake master cylinder as described in paragraph 10.
g) Install and adjust the brake light contact sensor as described in paragraph 17.
c) Install the cruise control vacuum valves.
i) Bleed the clutch and brake hydraulic systems as described in paragraph 2 and chapter 6 respectively.