Audi A4, S4

since 2000 release

Repair and operation of the car


Audi A4, S4
+ Introduction
+ Governing bodies and methods of safe operation
+ Current leaving and service
+ Engine
+ Cooling systems, heating and air conditioner
+ Power supply systems, release and decrease in toxicity of the fulfilled gases
+ Systems of electric equipment of the engine
+ Manual box of gear shifting
+ Automatic transmission
+ Coupling, power shafts and differential
- Brake system
   Specifications
   Removal of air from brake system
   Removal and installation of front brake shoes
   Removal and installation of blocks of brake mechanisms of back wheels
   Check of thickness of a brake disk
   Removal and installation of a brake disk / support
   Adjustment of the parking brake
   Removal and installation of the switch of a stoplight
   Removal and installation of a brake hose
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment





Removal and installation of front brake shoes

FN-3 support

By means of illustrations, find out execution of the support established on your car.

Forward brake FN3 mechanisms

1 — the Cover of a brake disk
2 — the Screw, 10nm
3 — the Brake hose. When replacing brake shoes not to turn off.
4 — the Holder. Fastens to the support case
5 — the Bolt, 10nm
6 — the Spring bracket
7 — the Brake pipeline, 15nm. It is rolled in the case of a support and connects to a brake hose. Thus it is necessary to hold for a hexagon of a brake hose. Watch reliable position of lock pads in the holder's grooves
8 — the wear sensor Socket. When replacing a brake shoe it is taken out from the holder (4)
9 — the Bolt with a gear fillet, 190nm. At repeated application clear teeths.
10 — Directing. Fastens to the wheel bearing case
11 — Brake shoes
All four blocks of one axis are surely replaced. Instruction: The internal block has an arrow. The arrow has to specify in the direction of rotation of a brake disk at the movement of the car forward. At the wrong installation can lead to emergence of noise.
External brake shoes have a sticky film on the return plates. The protective film before installation of blocks needs to be removed.

At achievement of the corresponding wear (2 – 3 mm) on the dashboard the control lamp lights up. Pay attention to various executions of brake shoes (the catalog of spare parts). Before installation of new blocks the support needs to be cleared carefully. On the directing surfaces of blocks it is necessary to apply a thin film of lithium G 052 142 A2 greasing of AUDI firm.
12 — the Lock spring. It is inserted into support case openings. Instruction: After installation the lock spring needs to be pressed into openings under the directing. At the wrong installation wear of an external block can not be compensated that will lead to increase in the course of a pedal of a brake
13 — the Brake disk. Both brake disks of one axis are surely replaced. For removal it is necessary to disconnect only a support
14 — the support Case. For replacement of brake shoes disconnect from the directing
15 — the Directing finger, 25nm
16 — the Cover
Instruction: All bolts and screws located outside have a sheeting.

Removal

 PERFORMANCE ORDER

  1. Mark the direction of its rotation on the tire. Turn off bolts of fastening of a wheel. Lift and establish forward part of the car on supports and remove a wheel.

Surely observe instructions in the Section In case of emergency.

If brake shoes are established again, they need to be marked at removal. Change by places of external and internal brake shoes, and also their shift with right on the left wheel is not allowed. Surely all brake shoes of forward wheels are replaced at the same time even if the limit of wear was reached by a brake shoe of one party.

  1. Uncover (shooters on an accompanying illustration) both directing fingers.
  1. Disunite the socket (1) index of wear of brake shoes in the presence of the last. Turn on 90 ° a lock level of the lower part of the plug.
  1. Take out the lower part of the plug from the holder.
  1. Hook a screw-driver and take out from an opening (the shooter on an accompanying illustration) a lock spring of a brake shoe.
  1. Turn out from a support both directing a finger.
  1. Remove the case of a support and fix it a wire to a suspension bracket.

Do not allow a tension of a brake hose.

  1. Remove an external brake shoe from the directing.
  2. Take out an internal brake shoe with a spring from the brake piston.

Installation

At the removed brake shoes do not press a brake pedal, otherwise the piston can be squeezed out from the case. In this case remove a support in a set and ask it to insert into place on HUNDRED.

 PERFORMANCE ORDER

  1. Before installation of blocks into place check palpation by fingers a brake disk. In the presence of flutes a disk it is possible to pierce (work HUNDRED) if it still allows thickness.
  2. Measure thickness of a brake disk, address to appropriate section.

Apply to cleaning of a disk only alcohol. Clear the directing surface and places of landing of blocks in mine of the case a rag. Do not use for this purpose the tool with sharp edges. Pay special attention to removal of the remains of a sticky film on adjacent surfaces of external brake shoes.

  1. Check a piston boot for existence of cracks. Immediately replace the damaged boot since the got dirt quickly leads to loss of tightness of a support. Thus it is necessary to sort a support (work HUNDRED).

At big wear of a brake shoe check ease of a piston stroke. For this purpose insert wooden whetstone into a support and ask the assistant to press a brake pedal slowly. The piston has to leave and enter easily. For check other support has to be established. Watch that the piston completely was not squeezed out. At a heavy piston stroke hand over a support in repair on HUNDRED. Press the piston the tool shown on an accompanying illustration.

It can be made also by means of wooden whetstone (the hammer handle). Thus watch that the piston not to warp the piston and not to damage a piston surface, and also a boot.

At cave-in of the piston brake fluid is squeezed out from the brake cylinder in the tank. Watch liquid in the tank, if necessary, suck away liquid by means of a siphon.

  1. Apply a plastic bottle which is intended only for this purpose to suction of brake fluid. Do not apply for this purpose a bottle to drinking liquid! Brake fluid is poisonous and should not be sucked away by a mouth through a hose at all. Apply for this purpose a siphon. When replacing brake shoes the level of brake fluid in the tank should not exceed MAX mark since liquid when heating extends. The following liquid gets on the main brake cylinder, destroys its covering and brings corrosion.
  2. Before installation of new brake shoes carefully clear them and grease with a thin layer of lithium G 052 142 A2 greasing.
  1. Insert an internal brake shoe with about a lock spring into the brake piston.


    1 — the Internal brake shoe of the right wheel
    2 — the Internal brake shoe of the left wheel

The internal brake shoe (has a spring) is supplied with an arrow. The arrow has to specify in the direction of rotation of a brake disk at the movement of the car forward. Incorrect installation (on other party of the car) can lead to emergence of noise.

  1. Remove a protective film from the return plate of an external brake shoe.
  1. Establish an external block on the directing.
  2. Install into place the case of a support and fix it on directing two directing fingers the moment 25nm.
  3. Establish into place both covers of fingers.
  1. Insert a spring into the support case.

After installation the lock spring needs to be pressed into openings under the directing. At the wrong installation wear of an external block can not be compensated that will lead to increase in the course of a pedal of a brake.

  1. Fix wheels, observing the direction of rotation of wheels. Lower the car on wheels and only after that tighten fastening bolts cross-wise the moment 120nm.

Several times standing strongly press a brake pedal so that to feel resistance. Thus brake shoes adjoin to a disk and hold the working position.

  1. Check brake fluid in the tank, if necessary, add liquid to MAX mark.
  2. Carefully let's be earned extra to new brake shoes. For this purpose several times slow down the car from speed 80 to the speed of 40 km/h, without pressing strongly a brake pedal. Between braking let's a brake be cooled.

After installation of its new brake shoe it is necessary to earn extra. For this purpose the first 200 km of a way do not apply sharp braking without need.

In some regions brake shoes have to be utilized as special material. Local authorities have to provide necessary information on points of possible utilization.

Attention, carry out reliability control:

- Whether brake hoses are fixed?

- Whether the brake hose is fixed in the holder?

- Whether unions for removal of air are tightened?

- Whether enough brake fluid is filled in?

- On the working engine check tightness. For this purpose press a brake pedal by effort of 200 - 300 N (20 – 30 kg) during 10 pages. The pedal should not weaken. Check all accessions for tightness.

FNR-G60 support

By means of an illustration find out execution of the support established on your car. In the real subsection only differences from FN-3 support are considered.

Forward brake FNR-G60 mechanisms

1 — the Brake shoe. All 4 blocks of one axis are surely replaced. Check ease of the course of a support by its lateral shift. The internal block with a spring has a cable for the wear sensor. At achievement of the corresponding wear (2 – 3 mm) on the dashboard the control lamp lights up. Before installation of new brake shoes carefully clear a support. Apply a thin film of lithium G 052 142 A2 greasing on the directing surfaces of blocks. At installation connect a wear sensor cable
2 — Directing
3 — the Bolt with a gear fillet, 1 90nm. At repeated application clear teeths
4 — the Plug. It is inserted into the support case
5 — the Directing finger, 30nm
6 — the Cover
7 — the Brake disk. Surely it is necessary to replace both disks of one axis. For removal previously disconnect a support. Grease adjacent surfaces between a brake disk and a nave of a wheel with G 052 142 A2 greasing.
8 — Bolts of fastening of a wheel, 120nm
9 — Connection of the brake pipeline, 12nm

10 — the Brake pipeline. It is rolled in the case of a support and connects to a brake hose. Thus the hose needs to be held from a provorachivaniye for a hexagon. The hose as a result of installation should not be twisted. Watch the correct position of lock pads in grooves on the holder
11 — Connection of the brake pipeline to a support, 19nm
12 — the Holder. Fix to the support case. Attach the brake pipeline
13 — the Bolt, 25nm
14 — the support Case. For replacement of brake shoes disconnect from directing and fix a wire on a suspension bracket
15 — the Lock spring. It is inserted into support case openings. Instruction: After installation the lock spring needs to be pressed into openings under the directing. At the wrong installation wear of an external block can not be compensated that will lead to increase in the course of a pedal of a brake

Removal

 PERFORMANCE ORDER

  1. Record a brake disk one bolt of fastening of a wheel (the shooter on an accompanying illustration).
  1. Hook a screw-driver and remove a lock spring of brake shoes from the support case.
  2. Disunite turn the socket of the index of wear of brake shoes, pull up and disconnect an electric wire.
  3. Disconnect a brake hose from the holder.
  1. Uncover and turn out both directing a finger.
  1. Remove the case of a support and fix it a wire to a suspension bracket.
  2. Take out a block from the case of a support or remove from the directing.

Installation

 PERFORMANCE ORDER

  1. Insert a brake shoe with a lock spring and the index of wear into the support case.
  1. Insert into a support internal (1) and external (2) brake shoes and establish together on directing and a brake disk.
  1. Fix the support case with fingers on directing the moment 30nm. Watch that the brake hose was not twisted. Establish covers of fingers.
  1. Fix the plug of the index of wear and fix a wire in the holder.

C54 support

By means of an illustration find out execution of the support established on your car. In the real subsection only differences from FN-3 support are considered.

Forward brake C54 mechanisms

1 — the Cover of a brake disk
2 — the Screw, 10nm
3 — the Brake hose. When replacing brake shoes it is not disconnected
4 — the Spring bracket
5 — the Brake pipeline, 15nm. Screw in the case of a support and connect to a brake hose. Thus hold a hose for a hexagon from a provorachivaniye. Watch the correct provision of lock levels in grooves on the holder
6 — the Bolt which is self-stopped 30nm. Surely replace a bolt. At an otvorachivaniye and an inhaling hold the directing finger
7 — the Bolt with a gear fillet, 190nm. At repeated application clear teeths
8 — Directing with the directing fingers and a protective cap. The spare part, is delivered together with greasing on the directing finger

9 — the Brake disk. Both disks of one axis are surely replaced. For removal previously disconnect a support
10 — the Heat-shielding guard. It is inserted into the piston
11 — the support Case. For replacement of brake shoes it is disconnected from the directing. The brake hose is not disconnected
12 — the Holder. It is fixed on the support case
13 — the Bolt, 10nm
14 — Brake shoes. All 4 blocks of one axis are surely replaced. At achievement of the corresponding wear (2 – 3 mm) on the dashboard the control lamp lights up. Before installation of new blocks surely carefully clear a support. On the directing surfaces of blocks apply a thin film of G 000 650 greasing
15 — the Socket of the index of wear of brake shoes. When replacing blocks take out from the holder (16)
16 — the Holder

Removal

 PERFORMANCE ORDER

  1. Disunite turn the socket of the index of wear of brake shoes, pull up and disconnect an electric wire.
  1. Turn off bolts from the support case, thus holding the directing fingers from a provorachivaniye.
  1. Cast away the case of a support up and take out upward brake shoes.

Installation

 PERFORMANCE ORDER

  1. Establish into place brake shoes.
  2. Lower the case of a support down and tighten new bolts of fastening the moment 30nm.

In a repair kit there are 4 self-stopped bolts.