Front brakes FN3
- 1 - Brake disc cover
- 2 - Screw, 10nm
- 3 - Brake hose. Do not unscrew when replacing brake pads.
- 4 - Holder. Attaches to caliper body
- 5 - Bolt, 10nm
- 6 - Spring clip
- 7 - Brake pipeline, 15Nm. It is screwed into the caliper body and connected to the brake hose. In this case, it is necessary to hold the brake hose by the hexagon. Ensure that the locking tabs are securely positioned in the grooves of the holder
- 8 - Wear sensor connector. When replacing the brake pad, it is removed from the holder (4)
- 9 - Bolt with a toothed shoulder, 190Nm. When reapplying, clean the teeth.
- 10 - Guide. Attaches to wheel bearing housing
- 11 - Brake pads. Be sure to replace all four pads of one axle.
Note: The inner block has an arrow. The arrow must point in the direction of rotation of the brake disc when the vehicle is moving forward. If installed incorrectly, noise may be generated.
External brake pads have an adhesive film on the back plates. The protective film must be removed before installing the pads.
Upon reaching the appropriate wear (2 - 3 mm) the control lamp lights up on the instrument panel. Take a look at the different designs of brake pads (spare parts catalog). Before installing new pads, the caliper must be thoroughly cleaned. Apply a thin layer of lithium grease G 052 142 A2 from AUDI to the guide surfaces of the pads.
- 12 - Retaining spring. It is inserted into the holes of the caliper body. Note: Once installed in the holes, the retaining spring must be pressed under the guide. If installed incorrectly, outer pad wear may not be compensated for, resulting in increased brake pedal travel
- 13 - Brake disc. Be sure to replace both brake discs of the same axle. To remove, you need to disconnect only the caliper
- 14 - Caliper housing. To replace the brake pads, disconnect from the guide
- 15 - Guide pin, 25Nm
- 16 - Cover
Note: All external bolts and screws are coated.
Withdrawal
1. Mark the direction of rotation on the tire. Loosen the wheel bolts. Raise and support the front of the car and remove the wheel.
Caution: Be sure to follow the instructions in Section In case of emergency.
Caution: If the brake pads are to be reinstalled, they must be marked when removed. It is not allowed to change places of external and internal brake pads, as well as their rearrangement from the right to the left wheel. Be sure to replace all brake pads of the front wheels at the same time, even if the brake pad on one side has reached the wear limit.
2. Remove covers (arrows on the accompanying illustration) from both guide pins.
3. Disconnect the connector (1) brake pad wear indicator, if available. Rotate the locking bar on the bottom of the plug 90°.
4. Remove the lower part of the plug from the holder.
5. Pry with a screwdriver and remove from the hole (arrow on accompanying illustration) brake pad retaining spring.
6. Turn out from a support both directing fingers.
7. Remove the caliper body and secure it with wire to the suspension.
Caution: Do not overstretch the brake hose.
8. Remove the outer brake shoe from the guide.
9. Remove the inner brake shoe with spring from the brake piston.
Installation
Caution: When the brake pads are removed, do not press the brake pedal, otherwise the piston may be squeezed out of the housing. In this case, remove the caliper as a set and ask him to put it in place at the service station.
1. Before installing the pads in place, check the brake disc by feeling with your fingers. In the presence of grooves, the disc can be machined (service station work), if the thickness still allows it.
2. Measure the thickness of the brake disc, refer to the relevant Section.
Caution: Only use alcohol to clean the disc. Clean the guide surface and the landing sites of the pads in the body shaft with a rag. Do not use a tool with sharp edges for this. Pay special attention to the removal of adhesive film residues on the adjacent surfaces of the outer brake pads.
3. Check the piston boot for cracks. Replace a damaged boot immediately, as Penetrating dirt quickly leads to loss of tightness of the caliper. In this case, you will have to disassemble the caliper (service station work).
Caution: If the brake pad is 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 in and out easily. To check, another caliper must be installed. Make sure that the piston is not completely squeezed out. If the piston stroke is heavy, have the caliper repaired at a service station. Press the piston with the tool shown in the accompanying illustration.
Warning: This can also be done with a block of wood (hammer handle). At the same time, make sure that the piston does not warp the piston and do not damage the piston surface, as well as the boot.
Caution: When the piston is pushed in, the brake fluid is forced out of the brake cylinder into the reservoir. Keep an eye on the liquid in the tank, if necessary, suck out the liquid with a siphon.
4. 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 and must never be sucked out by mouth through a hose. Use a siphon for this. When replacing the brake pads, the brake fluid level in the reservoir must not exceed the MAX mark, as liquid expands when heated. Escaping fluid enters the main brake cylinder, destroys its coating and causes corrosion.
5. Before installing new brake pads, thoroughly clean them and lubricate them with a thin layer of lithium grease G 052 142 A2.
6. Insert the inner brake shoe with retaining spring into the brake piston.
- 1 - Internal brake pad of the right wheel
- 2 - Internal brake pad of the left wheel
Caution: Internal brake pad (has a spring) provided with an arrow. The arrow must point in the direction of rotation of the brake disc when the vehicle is moving forward. Wrong installation (to the other side of the car) may cause noise.
7. Remove the protective film from the back plate of the outer brake pad.
8. Install the outer shoe on the guide.
9. Reinstall the caliper body and secure it to the guide with two guide fingers to the moment 25Nm.
10. Replace both finger covers.
11. Insert the spring into the caliper body.
Caution: Once installed in the holes, the retaining spring must be pressed under the guide. If installed incorrectly, outer pad wear may not be compensated for, resulting in increased brake pedal travel.
12. Fasten the wheels, observing the direction of rotation of the wheels. Lower the car onto the wheels and only then tighten the mounting bolts crosswise to the torque 120Nm.
Caution: Press the brake pedal firmly several times while standing until resistance is felt. Thus, the brake pads are adjacent to the disc and occupy their working position.
13. Check the brake fluid in the reservoir, if necessary, add fluid to the MAX mark.
14. Gently let the new brake pads run in. To do this, brake the car several times from a speed of 80 to a speed of 40 km / h without pressing the brake pedal hard. Let the brake cool down between braking.
Caution: After installing a new brake pad, it must be run in. To do this, do not apply sudden braking unnecessarily for the first 200 km of the road.
Warning: In some regions, brake pads must be disposed of as special material. The necessary information about the points of possible disposal should be provided by local authorities.
Attention, check the reliability:
- Are the brake lines secured?
- Is the brake hose fixed in the holder?
- Are the bleed fittings tight?
- Has sufficient brake fluid been added?
- With the engine running, check 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 loosen. Check all connections for tightness.
Caliper FNR-G60
Using the illustration, find out the version of the caliper installed on your car. This subsection only discusses the differences from the FN-3 caliper.
Front brakes FNR-G60
- 1 - Brake shoe. Be sure to replace all 4 pads of one axle. Check the ease of movement of the caliper by moving it sideways. The inner shoe with a spring has a cable for the wear sensor. Upon reaching the appropriate wear (2 - 3 mm) the control lamp lights up on the instrument panel. Clean the caliper thoroughly before installing new brake pads. Apply a thin film of lithium grease G 052 142 A2 to the pad guide surfaces. When installing, connect the wear sensor cable
- 2 - Guide
- 3 - Bolt with toothed shoulder, 1 90Nm. Clean teeth when reapplying
- 4 - Bushing. Inserted into the caliper body
- 5 - Guide pin, 30nm
- 6 - Cover
- 7 - Brake disc. Be sure to replace both disks of the same axle. To remove, first disconnect the caliper. Apply grease G 052 142 A2 to the adjacent surfaces between the brake disc and the wheel hub.
- 8 — Bolts of fastening of a wheel, 120Nm
- 9 — Accession of the brake pipeline, 12Nm
- 10 - Brake pipeline. It is screwed into the caliper body and connected to the brake hose. In this case, the hose must be kept from turning by the hexagon. The hose must not twist during installation. Make sure that the locking tabs are correctly positioned in the slots on the holder
- 11 - Attaching the brake pipeline to the caliper, 19Nm
- 12 - Holder. Attach to caliper body. Attach the brake pipeline
- 13 - Bolt, 25Nm
- 14 - Caliper body. To replace the brake pads, detach from the rail and wire onto the hanger
- 15 - Retaining spring. It is inserted into the holes of the caliper body. Note: Once installed in the holes, the retaining spring must be pressed under the guide. If installed incorrectly, outer pad wear may not be compensated for, resulting in increased brake pedal travel
Withdrawal
1. Fix the brake disc with one wheel bolt (arrow on accompanying illustration).
2. Pry with a screwdriver and remove the retaining spring of the brake pads from the caliper housing.
3. Disconnect the brake pad wear indicator connector by turning, pull up and disconnect the electrical wire.
4. Disconnect a brake hose from the holder.
5. Remove the covers and unscrew both guide pins.
6. Remove the caliper body and secure it with wire to the suspension.
7. Remove the block from the caliper body or remove from the guide.
Installation
1. Insert the brake shoe with retaining spring and wear indicator into the caliper body.
2. Insert into the caliper the inner (1) and external (2) brake pads and install together on the guide and brake disc.
3. Fasten the caliper body with fingers on the guide with torque 30Nm. Be careful not to twist the brake hose. Install finger covers.
4. Lock the wear indicator plug and secure the wire in the holder.
Caliper C54
Using the illustration, find out the version of the caliper installed on your car. This subsection only discusses the differences from the FN-3 caliper.
Front brakes C54
- 1 - Brake disc cover
- 2 - Screw, 10nm
- 3 - Brake hose. Doesn't come off when changing brake pads
- 4 - Spring clip
- 5 - Brake pipeline, 15Nm. Screw into the caliper body and connect to the brake hose. At the same time, hold the hose by the hexagon against turning. Ensure the correct position of the locking bars in the grooves on the holder
- 6 - Self-locking bolt, 30Nm. Be sure to replace the bolt. When loosening and tightening, hold the guide pin
- 7 - Bolt with a toothed shoulder, 190Nm. Clean teeth when reapplying
- 8 - Guide with guide pins and a protective cap. Spare part, supplied with grease on guide pin
- 9 - Brake disc. Be sure to replace both disks of the same axis. To remove, first disconnect the caliper
- 10 - Heat shield. inserted into the piston
- 11 - Caliper housing. To replace the brake pads, it is detached from the guide. Brake hose won't disconnect
- 12 - Holder. Mounted on the caliper body
- 13 - Bolt, 10nm
- 14 - Brake pads. Be sure to replace all 4 pads of one axle. Upon reaching the appropriate wear (2-3 mm) the control lamp lights up on the instrument panel. Be sure to thoroughly clean the caliper before installing new pads. Apply a thin layer of lubricant G 000 650 to the guide surfaces of the pads
- 15 - Brake pad wear indicator connector. Remove from holder when replacing pads (16)
- 16 - Holder
Withdrawal
1. Disconnect the brake pad wear indicator connector by turning, pull up and disconnect the electrical wire.
2. Remove the bolts from the caliper body while holding the guide pins from turning.
3. Tilt up the caliper housing and take out the brake pads.
Installation
1. Reinstall the brake pads.
2. Lower the caliper body down and tighten the new mounting bolts to the torque 30Nm.
Caution: There are 4 self-locking bolts in the repair kit.
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