brake pads AUDI A4 1999 B5 / 1.G Front Brake Service Workshop Manual

46-2


Note:
CAUTION!
Do not allow the caliper to hang by the brake
hose. The unsupported weight can stretch and
damage the hose.
Install complete repair kit.
After installing the brake pads, depress the
brake pedal firmly several times before moving
the vehicle to properly seat the brake pads in
their normal operating position.
The brakes can be tested on a commercial
brake dynamometer provided the speed of the
two dynamometer drive rollers is not more than
5.5 km/h (3.3 mph).
Tightening torque for the brake lines is 15 Nm
(11 ft lb)
1 -
Brake hose
Do not disconnect the brake hose from the
caliper when replacing brake pads.
2 -
Caps Remove for access to guide pin
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46-3


3 -
Guide pin
25 Nm (18 ft lb)
4 -
Brake line 15 Nm (11 ft lb)Install into caliper housingWhen tightening to brake hose, counter
hold on brake hose hex Make sure lugs are properly seated in
retainer grooves
5 -
Brake caliper housing Unbolt from brake carrier for replacing
brake pads Servicing brake caliper 47
-2
6 -
Ribbed bolt
125 Nm (92 ft lb)Clean ribbing if re-using
7 -
Brake carrier Bolt to wheel bearing housing
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46-4


CAUTION!
The inner brake pad (with expanding spring) is
marked with an arrow that must point in the
direction of rotor rotation when the vehicle is
moving forward. Incorrect installation can result
in excessive noise.
Note:
Before installing new brake pads, thoroughly clean
the brake calipers (free of grease). Pay particular
attention to removing any adhesive residue from
the outer brake pad contact surfaces. 8 -
Brake pads

Outer pads have an adhesive with a protective
sheet on the backing plate; remove this sheet
before installing
Different versions parts catalogue microfiche Always replace as a set on both wheels of an
axle
Removing and installing page 46
-7
Brake pad wear limit (friction material): 2 mm
(0.08 in.)
Brake pad wear limit (including backing plate): 7
mm (0.28 in.)
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46-7

Teves/Ate brake pads, removing and
installing


Removing

Note:
If brake pads are to be re-used, mark their
installed positions when removing. Re-install in
the same positions, otherwise the car may pull to
one side!

- Raise vehicle.

- Remove wheels.

- Use screwdriver to pry brake pad retaining spring out of brake caliper
housing, and remove spring.

- Remove top and bottom caps (arrows).
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46-10

- Once spring ends are seated in holes, press
retaining spring under brake carrier.

CAUTION!

If the spring is not installed correctly, the
outer brake pad alignment mechanism will
not be able to compensate for wear, and
increased brake pedal travel will result.

Note:
Depress the brake pedal firmly several times
while the car is stationary so that the brake pads
adjust to their normal operating positions.

- Check brake fluid level and top up if
necessary.
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46-12


Note:

Install complete repair kit.
After installing the brake pads, depress the
brake pedal firmly several times before moving
the vehicle to properly seat the brake pads in
their normal operating position.
The brakes can be tested on a commercial
brake dynamometer provided the speed of the
two dynamometer drive rollers is not more than
5.5 km/h (3.3 mph).
Tightening torque for the brake lines is 15 Nm
(11 ft lb).
1 -
Torx bolt
Always replace25 Nm (18 ft lb)Remove and install using commercially
available Torx socket T40 Bolts are included in the repair kit for the
brake pads
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46-13


CAUTION! 2 -
Brake disc
Always replace as a set on both wheels of
an axle Ensure adequate thicknessTo remove, first unbolt brake caliper
Internally ventilated brake discDiameter: 245 mm (9.65 in.)Thickness: 30 mm (1.18 in.)Wear limit: 28 mm (1.10 in.)
3 -
Brake caliper

Do not allow the caliper to hang by the brake
hose. The unsupported weight can stretch
and damage the hose.
Secure the brake caliper with a piece of wire
in order to relieve the stress on the brake
hose.
With the exception of replacing brake pads
page 46
-16
and servicing front brake calipers
page 46
-11
, no further repairs may be
performed to the brake caliper
4 -
Clamping spring
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46-14


5 -
Ribbed bolt
200 Nm (148 ft lb)Clean ribbing if re-using
6 -
Brake line 15 Nm (11 ft lb)
7 -
Retaining spring
8 -
Harness connector Only on models with wear indicators
9 -
Brake hose Do not disconnect the brake hose from the
caliper when replacing brake pads.
10 -
Bolt 25 Nm (18 ft lb)
11 -
Bracket Bolt to brake caliper housingInstall harness connector for brake pad
wear indicator
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46-15


12 -
Harness holder
Only on models with wear indicatorsInstall harness for brake pad wear indicator
into harness holder
13 -
Brake pads Always replace as a set on both wheels of
an axle Different left and right sidesRemoving and installing page 46
-16
With wear indicator
Once wear limit is reached (3 mm, 0.12
in.), warning light in instrument panel
comes on Brake pad thickness: 14 mm (0.55 in.)Outer pads have an adhesive with a
protective sheet on the backing plate;
remove this sheet before installing
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46-16

Double piston front caliper brake pads,
removing and installing


Removing

Note:
If brake pads are to be re-used, mark installed
positions when removing. Re-install at the same
point, otherwise the car may pull to one side!

- Raise vehicle.

- Remove wheels.

WARNING!
Brake fluid is poisonous and must never be removed by siphoning
with your mouth.
CAUTION! - Secure brake disc with wheel bolt (left arrow).
-
Remove both Torx bolts for outer brake pads (right arrows).
Extract part of the brake fluid from the brake fluid reservoir before
pushing back the pistons. If this is not done, particularly if the brake fluid has been topped
up in the meantime, brake fluid may flow out and cause damage.
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