Audi A3

since 1997 of release

Repair and car operation



Audi A3
+ Maintenance instruction
+ Current leaving and service
+ Engine
+ Systems of cooling, heating
+ the Power supply system and production of the fulfilled gases
+ engine Electric equipment
+ Manual box of gear shifting
+ Automatic transmission and models with a full drive
+ Coupling and power shafts
- Brake system
   Replacement of forward brake shoes
   Removal and installation of disk 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
   Brake liquid
   Air removal from brake system
   Removal and installation of a brake hose
   Check of the amplifier of a brake
   Removal, installation and adjustment of the switch of a stoplight
   Removal and installation of the lever and cable of the parking brake
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment
+ Elektroskhema







Replacement of forward brake shoes

GENERAL INFORMATION

Forward brake FS-III mechanisms

1–the screw with a crosswise shliyets
2–brake disk. Replace only completely on all axis. For removal it is necessary to disconnect a support previously.
3–brake shoes. All 4 blocks of one axis are replaced surely.
4–support
5–a directing finger, 30 N • m
6–cover
7–sealing ring. Surely replace.
8–brake hose. For replacement of blocks it is not necessary to turn on.
9–hollow bolt, 35 N • m
10-guard
11-bolt, 7 N • m
12-case of the bearing of a wheel
13-the screw with an internal shestigrannik, 8 N • m
14-sensor of number of turns of ABS. Before installation clear a reception an opening and grease with AUDI greasing – G000650
15-wheel bearing
16-lock ring
17-a nave with a rotor. Instruction: All bolts located outside have an anticorrosive covering. Therefore it is necessary to apply only original spare bolts of fastening.

Forward brake mechanism. FN-3 support

1–the screw with a crosswise shliyets
2–brake disk. Replace only completely with axes. For removal it is necessary to disconnect a support previously.
3–brake shoes. The external brake shoe on a reverse side has the pasted film. After block installation the film is necessary for removing. Replace only completely on all axis.
Instruction: Before installation of new blocks carefully clear supports of pollution (degrease). Thus pay special attention to removal of the remains of a film on adjacent surfaces of external blocks.
4–stopper. Insert into both openings of the case of a support.
5–the directing. The damaged covers replace. In a repair kit there is a pillow with greasing. It should be applied to greasing of directing fingers.
6–support case
7–a directing finger, 30 N • m
8–cover
9–sealing ring. Surely replace.
10-brake hose. For replacement of blocks it is not necessary to turn on.
11-hollow bolt, 35 N • m
12-a bolt with edges, 125 N • m. Before installation clear an adjacent surface and a carving.
13-bolt, 7 N • m
14-guard
15-case of the bearing of a wheel
16-the screw with an internal shestigrannik, 8 N • m
17-sensor of number of turns of ABS. Before installation clear a reception an opening and grease with AUDI greasing – G000650
18-wheel bearing
19-lock ring
20-a nave with a rotor. Instruction: All bolts located outside have an anticorrosive covering. Therefore it is necessary to apply only original spare bolts of fastening.

FS-III support

ATTENTION

All bolts located outside, have an anticorrosive covering. Therefore it is necessary to apply only original spare bolts.
There are two various executions of a brake of a forward wheel. Therefore, using an illustration find out, what execution is established on your car.


REMOVAL


ATTENTION

Brake shoes are object of control of the General rules of the admission to operation (ABE). Besides, plant – the manufacturer they are intended for installation on a certain model of the car. Therefore it is recommended to apply only brake shoes resolved by the manufacturer.


PERFORMANCE ORDER
1. Mark paint the provision of the corresponding forward wheel concerning a nave. It will allow to establish at assembly an otbalansirovanny wheel in its former situation. Weaken bolts of fastening of a wheel on the car standing on the earth. Lift a forward part of the car, put it on supports and remove a forward wheel.
ATTENTION

If brake shoes are established again, before removal they are necessary for marking. Shift of brake shoes outside inside and on the contrary or from the left wheel on right is not allowed. Surely replace at the same time all blocks of a forward wheel even if only one of them reached a wear limit.


2. Remove covers – 1–from both directing fingers. Twist both directing fingers a face key.
3. Fix a support a wire to a suspension bracket.

ATTENTION

Do not lower a support down as it can lead to a pulling of a brake hose.


4. Take out brake shoes.
INSTALLATION
ATTENTION

Do not press a brake pedal at the removed blocks. Otherwise the piston will be squeezed out from the case. In this case remove a support in a set and insert it into place in conditions HUNDRED.


5. Clear directing surfaces and places of landing of blocks in mine a rag and alcohol. Do not apply for this purpose the solvents containing mineral oils, or the tool with sharp edges.
ATTENTION

To cleaning of a brake apply only alcohol.


6. Before installation of blocks check a brake disk, having felt it fingers. At existence задиров a brake disk it is possible to pierce (work HUNDRED) if it has even sufficient thickness.
7. Measure thickness of a disk, thus address to subsection Check of thickness of a brake disk.
8. Check existence of cracks on a piston boot. In the presence of damages a boot at once replace, as the got dirt quickly leads to loss of tightness of a support. The support for this purpose should understand (work HUNDRED).
ATTENTION

At considerable wear of brake shoes 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 move easily in both parties. For check it is necessary to put other support. Pay attention to completely not to squeeze out the piston. At a heavy piston stroke the support is subject to repair (work HUNDRED).


9. By means of the adaptation return the piston back. It can be made also by means of whetstone of a tree of firm breeds (the hammer handle). Thus watch that the piston did not warp and not to damage a piston and boot surface.

ATTENTION

At a piston otzhimaniye, in the tank brake liquid is squeezed out. Watch intake of liquid in the tank. If necessary remove surpluses.
To an otsasyvaniye of brake liquid apply a plastic bottle which intends only for this purpose. Do not apply for this purpose a bottle to drinking liquid! Brake liquid is poisonous. By no means it is impossible to suck away it a mouth through a hose. Apply to this purpose a siphon. After replacement of brake shoes liquid level in a tank should not exceed a mark of MAX in a tank since when heating brake liquid extends. Following liquid flows down on the brake cylinder, destroying a covering and leading to corrosion.


10. Insert brake shoes in directing a support.
11. Establish a support at first from below (an arrow on an illustration).
ATTENTION

The pin (arrow) of a support should stand behind directing cases of wheel bearings.


12. Fix a support with both directing fingers on the case of wheel bearings the moment
30 N • m.
13. Establish both covers of fingers.
14. Establish both lobbies of a wheel so that the markings put at removal, coincided. Wrap bolts of fastening of a wheel. Lower the car on wheels and wrap bolts of fastening of a wheel a cross – crosswise the moment
120 N • m.
ATTENTION

Several times strongly press a brake pedal so that distinct resistance of a pedal was felt. Thus, blocks will lie down to a brake disk and will take the place.


15. Check level of brake liquid in the tank. If necessary add to MAX mark.
16. Carefully let's be earned extra to new brake shoes. For this purpose several times brake the car since speed 80 to 40 km/h, slightly pressing a pedal. Between braking let's to a brake be cooled.
ATTENTION

After installation of their new blocks it is necessary to earn extra. For this purpose at movement on distance of the first 200 km it is not necessary to brake strongly without need the car.
In a number of regions brake shoes should be utilized as a special material. Local authorities should inform drivers on places of the allowed utilization.
inspect reliability:

– Whether fastenings of brake hoses are reliably tightened?
– Whether the brake hose in the holder is fixed?
– Whether unions of removal of air are tightened?
– Whether it is enough in the tank of brake liquid?
– At the working engine check tightness of system. For this purpose press a brake pedal effort of 200-300 N (20-30 kg) during 10 pages. The pedal should not depart. Check on tightness all connections.


FN-3 support
REMOVAL
ATTENTION

Brake shoes are object of control of the General rules of the admission to operation (ABE). Besides, plant – the manufacturer they are intended for installation on a certain model of the car. Therefore it is recommended to apply only brake shoes resolved by the manufacturer.


17. Mark paint the provision of the corresponding forward wheel concerning a nave. It will allow to establish at assembly an otbalansirovanny wheel in its former situation. Weaken bolts of fastening of a wheel on the car standing on the earth. Lift a forward part of the car, put it on supports and remove a forward wheel.
ATTENTION

If brake shoes are established again, before removal they are necessary for marking. Shift of brake shoes outside inside and on the contrary or from the left wheel on right is not allowed. Surely replace at the same time all blocks of a forward wheel even if only one of them reached a wear limit.


18. Remove covers – 1–from both directing fingers. Twist both directing fingers a key for an internal shestigrannik.
19. Hook a screw-driver and remove clamps of brake shoes.
20. Twist both directing fingers from a support.
21. Remove a support and adhere it a wire at a body.
ATTENTION

Do not lower a support down as it can lead to a pulling of a brake hose.


22. Take out an external block from a brake board.
23. Take out an internal block (with a clamp) from the piston.
INSTALLATION
ATTENTION

Do not press a brake pedal at the removed blocks. Otherwise the piston will be squeezed out from the case. In this case remove a support in a set and insert it into place in conditions HUNDRED.


24. Clear directing surfaces and places of landing of blocks in mine a rag and alcohol. Do not apply for this purpose the solvents containing mineral oils or the tool with sharp edges.
ATTENTION

To cleaning of a brake apply only alcohol.


25. Before installation of blocks check a brake disk, having felt it fingers. At existence задиров a brake disk it is possible to pierce (work HUNDRED) if it has even sufficient thickness.
26. Measure thickness of a disk, thus address to subsection Check of thickness of a brake disk.
27. Check existence of cracks on a piston boot. In the presence of damages a boot at once replace, as the got dirt quickly leads to loss of tightness of a support. The support for this purpose should understand (work HUNDRED).
ATTENTION

At considerable wear of brake shoes 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 move easily in both parties. For check it is necessary to put other support. Pay attention to completely not to squeeze out the piston. At a heavy piston stroke the support is subject to repair (work HUNDRED).


28. By means of the adaptation press the piston. It can be made also by means of whetstone of a tree of firm breeds (the hammer handle). Thus watch that the piston did not warp and not to damage a piston and boot surface.

ATTENTION

By pressing the piston in the tank brake liquid is squeezed out. Watch intake of liquid in the tank. If necessary remove surpluses.
To an otsasyvaniye of brake liquid apply a plastic bottle which intends only for this purpose. Do not apply for this purpose a bottle to drinking liquid! Brake liquid is poisonous. By no means it is impossible to suck away it a mouth through a hose. Apply to this purpose a siphon. After replacement of brake shoes liquid level in a tank should not exceed a mark of MAX in a tank as when heating brake liquid extends. Following liquid flows down on the brake cylinder, destroying a covering and leading to corrosion.


29. Insert an internal brake shoe (with a clamp) into the brake piston.

ATTENTION

The internal brake shoe (with a clamp) has an arrow, thus address to an accompanying illustration. The arrow should indicate in the direction of rotation of a brake disk at car movement forward. At the wrong installation (on other party of the car) it can bring to noise emergence.


30. Establish on directing external brake shoe.
31. Remove a protective film from a return plate of an external brake shoe.
32. Establish a support and fix it both directing fingers to directing the moment 30Н • m.
33. Establish both covers of fingers.
34. Insert a clamp – 1–into a support.

ATTENTION

After installation in both openings the clamp should be pressed under the directing. At the wrong installation the external block despite wear is not established that leads to increase in a course of a pedal.


35. Establish both lobbies of a wheel so that the markings put at removal, coincided. Wrap bolts of fastening of a wheel. Lower the car on wheels and wrap bolts of fastening of a wheel a cross – crosswise моментом120 N • m.
ATTENTION

Several times strongly press a brake pedal so that distinct resistance of a pedal was felt. Thus, blocks will lie down to a brake disk and will take the place.


36. Check level of brake liquid in the tank. If necessary add to MAX mark.
37. Carefully let's be earned extra to new brake shoes. For this purpose several times brake the car since speed 80 to 40 km/h, slightly pressing a pedal. Between braking let's be cooled to a brake.
ATTENTION

After installation of their new blocks it is necessary to earn extra. For this purpose at movement on distance of the first 200 km it is not necessary to brake strongly without need the car.
In a number of regions brake shoes should be utilized as a special material. Local authorities should inform drivers on places of the allowed utilization.
inspect reliability:

– Whether fastenings of brake hoses are reliably tightened?
– Whether the brake hose in the holder is fixed?
– Whether unions of removal of air are tightened?
– Whether it is enough in the tank of brake liquid?
– At the working engine check tightness of system. For this purpose press a brake pedal effort of 200-300 N (20-30 kg) during 10 pages. The pedal should not depart. Check on tightness all connections.