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Service
Workshop Manual
Audi A8 2003 ➤

Brake system

Edition 03.2013
Service Department. Technical Information
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

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Summary of Contents for Audi A8 2003

  • Page 1: Brake System

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 2 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not 45 - Anti-lock brake system permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 3: Table Of Contents

    Electronic stabilisation program Bosch 5.7 ........permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document.
  • Page 4 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability Brake servo/ brake master cylinder - exploded view ......112 with respect to the correctness of information in this document.
  • Page 5 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 6 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 7: Technical Data

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability brake disc hub as a wear limit with respect to the correctness of information in this document.
  • Page 8 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not often found on the friction surface of the brake discs. Hairline permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability cracks up to a length of 10 mm do not present a technical with respect to the correctness of information in this document.
  • Page 9 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 10: Assessment Of Ceramic Brake Discs

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 11: Superficial Cracks In Cooling Channel Lands

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not When doing so, always renew the brake pads on both sides of permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability the axle.
  • Page 12: Edge Fractures

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 13: Assessing Degree Of Wear On Ceramic Brake Discs

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 14 Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability Depending on the version, the min‐ with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 15 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not cleaning brake discs or other parts of the brake system using permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability compressed air.
  • Page 16 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not ♦ there has been a technical modification to the replacement permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability brake disc (indicated by changed part number).
  • Page 17: Wear Assessment By Checking Thickness Of Brake Disc

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability The minimum permissible thickness of the brake disc is engraved with respect to the correctness of information in this document.
  • Page 18: Wear Assessment By Weighing Brake Disc

    The brake disc must be cleaned and dry before it is weighed. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 19: Wear Assessment By Weighing Brake Disc

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Depending on the version, the minimum permissible weight for a permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability used brake disc is stamped on the brake disc hub. The disc must with respect to the correctness of information in this document.
  • Page 20 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 21: Brake Test

    AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 22 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability – Rear wheels, min. speed = 3 km/ h, max. speed = 9 km/h.
  • Page 23: Brake Fluid

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 24: Anti-Lock Brake System

    ⇒ VAS 505x vehicle diagnostic, testing and information Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability system .
  • Page 25 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 26: Connecting Vas 505X And Selecting Functions

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 27: With Respect To The Correctness Of Information In This Document. Copyright By Audi Ag

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Select “Brake system” on the display. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 28: Permitted Unless Authorised By Audi Ag. Audi Ag Does Not Guarantee Or Accept Any Liability 3 Electronic Stabilisation Program Bosch 5.7

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not ❑ Do not disconnect con‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability nector (42 pin) before with respect to the correctness of information in this document.
  • Page 29 ⇒ page 32 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability 12 - Diagnostic socket with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 30: Hydraulic Unit And Brake Lines

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not 10 - Nut with washer permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability ❑ Tightening torque 9 Nm with respect to the correctness of information in this document.
  • Page 31 ♦ Torque wrench - V.A.G 1331/- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability ♦ Brake pedal actuator - V.A.G 1869/2- with respect to the correctness of information in this document.
  • Page 32 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 33 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 34: Renewing Abs Control Unit J104

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Perform final control diagnosis after attaching brake lines to permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 35 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 36 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Tighten bolts -1- to -6- in the sequence shown. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 37: Removing And Installing Parts Of Abs System On Front And Rear Axles

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 38: Removing And Installing Parts Of Abs System On Rear Axle

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not shaft. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 39 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 40: Removing And Installing Parts Of Esp System

    To ensure a secure fit, the switch may only be fitted once. ♦ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 41: Removing And Installing Lateral Acceleration Sender G200 And Yaw Rate Sender G202

    ⇒ Rep. gr. 48 ⇒ Vehicle diagnostic, testing and information sys‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability tem VAS 505x; "Guided Fault Finding" function with respect to the correctness of information in this document.
  • Page 42: Removing And Installing Parking Brake Switch

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability – Remove hexagon bolt - 1 - securing fluid reservoir and pull with respect to the correctness of information in this document.
  • Page 43 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 44: Brakes - Mechanism

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 45 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 46 Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability Brake line at brake pipe: 12 Nm ♦...
  • Page 47: Removing And Installing Brake Pads

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not cannot be adjusted, and the pedal permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability travel will be increased as a result.
  • Page 48 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Lever brake pad retaining spring out of brake caliper housing permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with a screwdriver and remove.
  • Page 49 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 50 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Check brake fluid level and top up if necessary. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 51: Renewing Brake Caliper

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Installing permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 52: Front Brakes (Pr 1Lj, 1Ll, 1Lm, 1Lk)

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 53 ❑ Wear limit ⇒ page 1 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG. ❑ Always renew on both sides of axle ❑...
  • Page 54: Removing And Installing Brake Pads

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Check the thickness of the brake disc when renewing the brake permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability pads. Refer to wear limit for brake disc. Wear limit with respect to the correctness of information in this document.
  • Page 55 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 56 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 57 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 58: Renewing Brake Caliper

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability The retaining spring must be pushed under the brake carrier after with respect to the correctness of information in this document.
  • Page 59 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not After installing the brake pads and before driving the vehicle, permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 60: Ceramic Front Brakes (Pr 1Lw)

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not the brake caliper. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 61 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not ❑ Bolt to wheel bearing housing permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 62 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not ❑ Do not twist hose when fitting permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability ❑ Ensure that lugs are properly seated in grooves in bracket.
  • Page 63: Detaching And Attaching Damper Spring

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability Mark brake pads when removing them if they are to be rein‐...
  • Page 64 – Turn connector 90° while using a screwdriver to release con‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 65 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not pressed underneath the guide pin so that it is under tension. If permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability the retaining spring is fitted incorrectly, the brake pads will be with respect to the correctness of information in this document.
  • Page 66: Removing And Installing Brake Caliper (Ceramic Brakes)

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability It is important to ensure that the pad wear indicator wire is inserted with respect to the correctness of information in this document.
  • Page 67 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 68: Detaching And Attaching Front Brake Disc (Ceramic Brakes)

    Take care not to twist brake hose. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability Caution with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 69: Renewing Front Brake Disc (Ceramic Brakes)

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability The brake disc ring and the brake disc hub are bolted together with respect to the correctness of information in this document.
  • Page 70 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Do not leave brake caliper hanging from brake hose but secure it permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability to bodywork using a suitable cable tie or wire. Take care that with respect to the correctness of information in this document.
  • Page 71: Rear Brakes, Electronic Parking Brake And Handbrake (Epb)

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Note permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 72 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not sides of axle permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 73: Removing And Installing Brake Pads (Rear Brakes)

    ❑ Tightening torque: 140 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability ❑ M12×1.5 x 75 with respect to the correctness of information in this document.
  • Page 74 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Note permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 75 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Enter “05” or “005” as “Display group number” in display zone permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability -2- via the keypad and confirm entry with “Q key” (resetting with respect to the correctness of information in this document.
  • Page 76 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 77 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 78 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability ♦ The prompt to enter a display group appears in display zone with respect to the correctness of information in this document.
  • Page 79 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 80: Brake Pedal (Lhd) - Exploded View

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not ❑ Tightening torque: 25 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 81 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 82: Removing And Installing Brake Pedal (Lhd Vehicles)

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 83: Removing And Installing Mounting Bracket

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not gr. 68 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 84: Overview Of Components: Electronic Parking Brake And Handbrake (Epb)

    ⇒ page 79 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability 6 - EPB control unit with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 85: Removing And Installing Control Unit For Electronic Parking Brake And Handbrake

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 86 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Note permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 87 Make sure you do not damage annular groove for seal and con‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability tact surface on actuator motor.
  • Page 88 – Push actuator motor connector into bracket. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability Note with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 89: Brakes - Hydraulics

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 90: Brake Calipers Fnr G60

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not cylinder, piston and seal. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 91: Removing And Installing Piston For Front Brake Caliper

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability – Force piston out of brake caliper housing using compressed with respect to the correctness of information in this document.
  • Page 92 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 93 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 94: Brake Calipers 2Fnr 42 Al

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability 9 - Protective cap with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 95: Removing And Installing Pistons For Front Brake Caliper

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 96 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Item -1-: Assembly tool for protective caps -T10146/5- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 97 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 98: Brembo Brake Calipers (18")

    ❑ Fit onto bleeder valve Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability 2 - Bleeder valve, 12 Nm with respect to the correctness of information in this document.
  • Page 99: Removing And Installing Pistons For Front Brake Caliper

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 100 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 101: Brake Caliper (Ceramic Brakes)

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not caliper or change the brake pads. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 102 ❑ Tightening torque: 25 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability 14 - Brake line connection at brake pipe with respect to the correctness of information in this document.
  • Page 103: Removing And Installing Pistons For Front Brake Caliper

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not pipe: 12 Nm permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 104 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Insert the seal into the brake caliper housing. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
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  • Page 117: Changing Brake Fluid

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  • Page 145: Repairing Brake Lines

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