Audi A4, S4

since 2000 of release

Repair and car operation


Audi A4, S4
+ Introduction
+ Governing bodies and receptions of safe operation
+ Current leaving and service
+ Engine
+ Systems of cooling, 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
   Air removal from brake system
   Removal and installation of forward 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

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

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 is necessary for clearing carefully. On directing surfaces of blocks it is necessary to apply a thin film lithium A2 G 052 142 greasing of AUDI firm.
12 — the Lock spring. It is inserted into openings of the case of a support. Instruction: After installation the lock spring is necessary for pressing into openings under the directing. At the wrong installation wear of an external block can not be compensated that will lead to increase in a 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, 25Нм
16 — the Cover
Instruction: All bolts located outside and screws have a sheeting.

Removal

 PERFORMANCE ORDER

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

Surely observe instructions in the Section In case of emergency.

If brake shoes are established again, it is necessary to mark them 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.

    Remove covers (arrows on an accompanying illustration) from both directing fingers.
    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 tip.
    Take out the lower part of the tip from the holder.
    Hook a screw-driver and take out from an opening (the shooter on an accompanying illustration) a lock spring of a brake shoe.
    Twist from a support both directing fingers.
    Remove the case of a support and fix it a wire to a suspension bracket.

Do not allow a tension of a brake hose.

    Remove an external brake shoe from the directing. 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 it can be squeezed out from the case. In this case a support remove in a set and ask it to insert into place on HUNDRED.

 PERFORMANCE ORDER

    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. Measure thickness of a brake disk, address to appropriate section.

To cleaning of a disk apply only alcohol. Directing surface and places of landing of blocks in mine of the case clear a rag. Do not apply for this purpose the tool with sharp edges. Special attention turn on removal of the remains of a sticky film on adjacent surfaces of external brake shoes.

    Check a piston boot on existence of cracks. The damaged boot immediately replace, since the got dirt quickly leads to loss of tightness of a support. Thus it is necessary to assort a support (work HUNDRED).

At big wear of a brake shoe check ease of a piston stroke. For this purpose insert into a support wooden whetstone and ask the assistant to press a brake pedal slowly. The piston should leave and enter easily. For check other support should 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 piston cave-in brake liquid 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.

    To an otsasyvaniye of brake liquid apply a plastic bottle which is intended only for this purpose. Do not apply for this purpose a bottle to drinking liquid! Brake liquid is poisonous and should not be sucked away by a mouth through a hose at all. Apply for this purpose a siphon. At replacement of brake shoes level of brake liquid in the tank should not exceed MAX mark since liquid when heating extends. Following liquid gets on the main brake cylinder, destroys its covering and brings corrosion. Before installation of new brake shoes carefully clear them and grease with a thin layer of lithium A2 G 052 142 greasing.
    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 should indicate in the direction of rotation of a brake disk at car movement forward. Incorrect installation (on other party of the car) can lead to emergence of noise.

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

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

    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 120Нм.

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

    Check brake liquid in the tank, if necessary, add liquid to MAX mark. Carefully let's be earned extra to new brake shoes. For this purpose several times brake the car since speed 80 till speed of 40 km/h, without pressing strongly a brake pedal. Between braking let's to 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 without need sharp braking.

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

Attention, carry out reliability control:

- Whether brake hoses are fixed?

- Whether the brake hose in the holder is fixed?

- Whether unions for air removal are tightened?

- Whether enough of brake liquid is filled in?

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

FNR-G60 support

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

Forward brake FNR-G60 mechanisms

1 — the Brake shoe. All 4 blocks of one axis are surely replaced. Check ease of a 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 lithium A2 G 052 142 greasing on directing surfaces of blocks. At installation connect a cable of the sensor of wear
2 — Directing
3 — the Bolt with a gear fillet, 1 90Нм. At repeated application clear teeths
4 — the Plug. It is inserted into the support case
5 — the Directing finger, 30Нм
6 — the Cover
7 — the Brake disk. Surely it is necessary to replace both disks of one axis. For removal previously disconnect a support. Adjacent surfaces between a brake disk and a nave of a wheel grease with A2 G 052 142 greasing.
8 — Bolts of fastening of a wheel, 120Нм
9 — Connection of the brake pipeline, 12Нм

10 — the Brake pipeline. It is rolled in the case of a support and incorporates to a brake hose. Thus the hose is necessary for holding from a provorachivaniye for a shestigrannik. The hose as a result of installation should not be braided. Watch the correct position of lock pads in grooves on the holder
11 — Connection of the brake pipeline to a support, 19Нм
12 — the Holder. Fix to the support case. Attach the brake pipeline
13 — the Bolt, 25Нм
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 openings of the case of a support. Instruction: After installation the lock spring is necessary for pressing into openings under the directing. At the wrong installation wear of an external block can not be compensated that will lead to increase in a course of a pedal of a brake

Removal

 PERFORMANCE ORDER

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

Installation

 PERFORMANCE ORDER

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

Support С54

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

Forward brake C54 mechanisms

1 — the Cover of a brake disk
2 — the Screw, 10Нм
3 — the Brake hose. At replacement of brake shoes it is not disconnected
4 — the Spring bracket
5 — the Brake pipeline, 15Нм. Screw in the case of a support and connect to a brake hose. Thus hold a hose for a shestigrannik from a provorachivaniye. Watch the correct provision of lock levels in grooves on the holder
6 — the Bolt being self-stopped, 30Нм. A bolt surely replace. At an otvorachivaniye and an inhaling hold directing finger
7 — the Bolt with a gear fillet, 190Нм. At repeated application clear teeths
8 — Directing with directing fingers and a protective cap. The spare part, is delivered together with greasing on a 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, 10Нм
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 directing surfaces of blocks apply a thin film G 000 650 greasings
15 — the Socket of the index of wear of brake shoes. At replacement of blocks take out from the holder (16)
16 — the Holder

Removal

 PERFORMANCE ORDER

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

Installation

 PERFORMANCE ORDER

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

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