Audi Workshop Service and Repair Manuals

Removing and installing front brake pads - FBC-57 brakes   Note Always renew on both sides of axle. Special tools and workshop equipment required t  Torque wrench -V.A.G 1331- t  Ratchet -V.A.G. 1331/1- t  Piston resetting appliance -T10145- Removing   WARNING The retaining pins (4x) for the brake pads on the brake carrier must NOT be slackened –  Raise the vehicle. –  Remove wheels.   Note Mark brake pads when removing them if they are to be reinstalled. Reinstall in their original position to prevent uneven braking. –  Move brake hose clear from bracket -4-.

–  Release electrical wire towards the left -arrow A- from bracket -2- and detach.   WARNING The four retaining pins for the brake pads in the brake caliper must NOT be slackened. –  Press down centre of retaining spring -8-.

Note t  The spring is under tension; hold your hand over the spring to avoid risk of injury. t  When removing the spring, take care not to scratch or chip the paint on the brake caliper. –  Carefully detach retaining spring. –  Unplug electrical connector for brake pad wear indicator (front left).   Note The pad wear indicator is only fitted on the inner pad in the front left brake caliper. –  Unscrew both bolts -4- for guide pins and remove from brake caliper.

Caution Do NOT slacken bolts -6 and 9- –  Pull both guide pins slightly out of brake caliper to facilitate removal of caliper. –  Detach brake caliper. Do not leave brake caliper hanging from brake hose but secure it to bodywork using a suitable cable tie or wire. Take care that brake hose is not damaged by weight of brake components. –  Take brake pads out of brake caliper housing or from brake carrier.   WARNING The four retaining pins for the brake pads in the brake caliper must NOT be slackened. Installing –  Clean brake caliper. Use only methylated spirits to clean the brake caliper housing.   Note Before inserting new brake pads, press piston back into cylinder with resetting appliance. Before pressing the piston back, draw off brake fluid from the reservoir with a bleeder bottle. Otherwise, fluid can overflow and cause damage, particularly if the reservoir has been topped up.   WARNING Brake fluid is poisonous and must NOT be drawn off by sucking through a hose. –  Press piston back.

Use piston resetting appliance T10145. –  If fitted, pull protective foil off pad backplates.

–  Fit inner brake pad with retaining spring in brake caliper. Retaining spring -arrow- must be seated in brake piston.

–  Fit outer brake pad -2- in brake caliper. –  Press brake pad into caliper and insert locating device into aperture in brake caliper.

The backplate of the brake pad has a locating device -10-, which must fit securely in the aperture in the caliper.

WARNING Both brake pads must be seated under the retaining pins in the caliper. The brake caliper has two retaining pins on each side, which must not be slackened. –  Carefully fit brake caliper (with brake pads) over brake disc. –  Secure brake caliper to brake carrier with both guide pins -4-.

–  Fit retaining spring -8- on outer brake pad.

–	Press down centre of retaining spring -8- and fit centre tab of spring in hole -arrow- in brake caliper.

The tab of the retaining spring must be seated properly in the hole in the brake caliper, otherwise the spring can become detached and the pad would not be secured.   Note t  The spring is under tension; hold your hand over the spring to avoid risk of injury. t  When fitting the spring, take care not to scratch or chip the paint on the brake caliper. –  Attach electrical connector for pad wear indicator in bracket (front left).

–  Fit electrical wire -2- in bracket and turn to the right -arrow B- to secure. –  Fit brake hose in bracket -4-. –  Plug in electrical connector for brake pad wear indicator (front left). –  Fit wheels → Wheels and tyres; Rep. gr.44.   Note After installing the brake pads, depress the pedal firmly several times with the vehicle stationary, so that the pads are properly seated in their normal operating position. –  Check brake fluid level and top up if necessary.