AUDI A4 2000 B5 / 1.G Front Brake Service User Guide

- Insert retaining spring into brake caliper housing.
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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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46-11


Double piston front brake calipers,
servicing

WARNING!

Do not re-use fasteners that are worn or
deformed in normal use.
Some fasteners are designed to be used only
once, and are unreliable and may fail if used
a second time. This includes, but is not
limited to, nuts, bolts, washers, circlips and
cotter pins. Always follow recommendations
in this manual-replace these fasteners with
new parts where indicated, and any other
time it is deemed necessary by inspection.
To siphon brake fluid, always use a bleeder
bottle which is only used to siphon brake
fluid.
Brake fluid is poisonous and must NEVER be
removed by siphoning with your mouth.
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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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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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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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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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Use the bleeder bottle or a plastic bottle, which is used only for
brake fluid, for extracting the fluid. 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.
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- Push piston back into brake caliper housing.
- To do this use screwdriver inserted into floating caliper frame and
press frame outward.
- Remove outer brake pads first by pressing pads off brake caliper using
screwdriver.
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