Brake Pads, Removing And Installing, Brake Caliper Without Brake Pad Spring: Installing

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Install in the reverse order of removal while noting the following:

Always replace brake pads on the same axle at the same time.
Use the complete repair kit when installing new brake pads.
Components to be used when installing new brake pads. Refer to the appropriate Electronic Parts Information.

-- If the brake pads are being replaced, check the brake rotors for wear and damage. Refer to BRAKE ROTOR, CHECKING .

CAUTION:

Health risk due to toxic dust from the brake system.

Irreversible deposit of dust particles in the lungs. Breathing impairments may occur.

- Never blow out the brake system with compressed air.

Use only mineral spirits to clean the brake caliper.
Check the protective caps of the brake caliper pistons for damage and install the complete repair kit, if necessary. Refer to BRAKE CALIPER PISTON, REMOVING AND INSTALLING .

Fig 1: Suction Hose From The Brake Charger/Bleeder Unit

Courtesy of AUDI

CAUTION:

There is a risk of contamination and paint damage from leaking brake fluid.

- Check the brake fluid level before pushing the brake caliper piston back into the brake cylinders.

-- If the brake fluid is up to the "MAX" marking on used brake pads, it must be extracted.

-- Evacuate the brake fluid -2- in the brake fluid reservoir with the screen installed -1-, using the Brake Filling and Bleeding Equipment:VAS 6860 or Brake Charger/Bleeder Unit:VAS 5234 (example illustration).

-- Use the Piston Resetting Tool:T10145 to completely press back the brake caliper piston.

-- Clean the brake carrier -1- at the brake pad spring contact surfaces -arrow- and thinly coat them with grease.

Courtesy of AUDI

-- If reusing, install the marked brake pads in the same location.

-- Install the brake pads while paying attention to the installed position. Refer to Figure.

-- Place the brake pads -1- with the springs -2- into the brake carrier opening -3-.

Courtesy of AUDI

After installing the brake pads, ensure the proper seating of all springs -2-.

-- Push the brake caliper over the installed brake pads.

Fig 2: Identifying Guide Pins

Courtesy of AUDI

Make sure the brake hose is routed correctly.
Make sure the brake hose is not pinched, bent, twisted or rubbing against the vehicle.

-- Tighten the brake caliper bolts -arrows- by counterholding the guide pins -1 and 2-.

Check the brake pad wear indicator contact for damage and replace if necessary.
Make sure that the brake pad wear indicator contact fits correctly in the brake pad.
If the clips go missing, the brake pad wear indicator wire must be replaced.

-- Install the brake pad wear indicator sensor. Refer to BRAKE PAD WEAR INDICATOR WIRE, REMOVING AND INSTALLING .

-- Complete the "brake pads, removing" Function using the Vehicle Diagnostic Tester.

CAUTION:

Faulty brakes increase the risk of an accident.

- Make sure the brakes are working correctly before driving the vehicle for the first time.

-- With the vehicle stationary, firmly press the brake pedal several times so that the brake pads in the operating condition properly sit in their respective position.