Audi Workshop Service and Repair Manuals

Special tools and workshop equipment required

Removing

• ‒ Remove storage compartment, driver's side.

=> General Body Assembly; Repair group 68

Releasing brake pedal

Ensure that the brake light switch is removed.

•     1 -    Inserting release tool
  -T10006-
• ◆ Feed the tool in from below.
•     2 -    Releasing process
• ◆ Hold the brake pedal tight. Lift the catches off the ball head by a slight pull on the tool -arrow A-.
• ◆ Hold the tool tensioned so that the catches do not engage again on the ball head.
• ◆ Now, detach the brake pedal from the ball head -arrow B-.

• ‒ Fit bleeder hose and bleeder bottle to the front left brake caliper bleeder screw and open bleeder screw.
• ‒ Depress the brake pedal in order to pump out as much brake fluid as possible.
• ‒ Close front left bleeder screw.

• ‒ → Unscrew the bolt -3- attaching the brake fluid reservoir.
• ‒ Unplug the connector of the sender for the float warning indicator -2-.

• ‒ → Detach feed hose -1- for clutch master cylinder.

Notes:

• ◆ Protect the plenum chamber against any escaping brake fluid.
• ◆ The underside of the brake fluid reservoir clips into the brake master cylinder.

• ‒ To remove reservoir, press down locking lug and at the same time pull brake fluid reservoir out of sealing plugs.
• ‒ Remove brake fluid reservoir.

• ‒ → Detach brake pipes -3- and seal with the dummy plugs from repair kit Part No. 1H0 698 311 A.
• ‒ Disconnect vacuum hose -2-.
• ‒ Unscrew the bolts attaching the brake servo unit -1- (Torx T45).
• ‒ Remove brake servo with brake master cylinder.

• ‒ Unscrew the nuts attaching the brake master cylinder -1-.
• ‒ Carefully remove brake master cylinder from brake servo unit.

Pay special attention to the following on installation:

• ◆ Before installing brake master cylinder, clean any residual brake fluid off plenum chamber.
• ◆ When assembling brake master cylinder with brake servo unit, make sure push rod is properly positioned in brake master cylinder.

• ‒ Adjust brake light switch .
• ‒ Adjusting vent valve for cruise control system

Bleeding clutch hydraulic system:

• ‒ Connect V.A.G 1869 but do not switch on yet.
• ‒ Open bleeder screw on slave cylinder.
• ‒ Attach collector bottle hose.
• ‒ Switch on the bleeding appliance and allow about 100 cm3 of brake fluid to flow out of the clutch slave cylinder.
• ‒ Close bleed screw.
• ‒ Bleed brake system => Page 47-46