Contents: FN3 brake mechanisms ⬇ Replacing the pads ⬇ Removal and installation, repair of…⬇ FS-III brake mechanisms ⬇ Replacing the pads ⬇ Removal and installation, repair of…⬇
Note: Brake pads should be replaced in pairs and on both wheels of the same axle at the same time.
Note: If the pads are not being removed for replacement, i.e. will be reinstalled, mark them before removal so that they can be reinstalled in their original locations.
FN3 brake mechanisms
1. The parts of the FN3 front brake mechanism are shown in the illustration.
2.1. Front brake mechanism parts FN3 1. Bolt, 4 Nm; 2. Brake disc, ventilated, replaceable on both sides at the same time; 3. Brake pads with wear indicator, replaced in pairs, on both sides at the same time; 4. Retaining spring; 5. Anchor bracket; 6. Support; 7. Guide pin, 30 Nm; 8. Cap; 9. Brake hose with connection and hollow bolt, 35 Nm; 10. Bolt, 200 Nm, clean before reuse; 11. Bolt, 15 Nm; 12. Bracket; 13. Steering knuckle; 14. ABS sensor, before installation, clean the walls of the mounting hole and apply G052 112A3 grease to them; 15. Bolt, 8 Nm; 16. Brake mechanism shield; 17. Torx bolt, 12 Nm; 18. Hub assembly, with built-in sensor rotor 14
Replacing the pads
2. Jack up the car and place it on reliable supports. Remove the front wheel.
3. Using a screwdriver, press the retaining spring away from the caliper (see illustration) and take it off.
2.3. Releasing the spring
4. Disconnect the brake pad wear sensor wiring connector (see illustration).
2.4. Brake pad wear sensor connector
5. Remove the caps (see illustration) and turn out the guide pins located behind them. Remove the guide pins from the caliper. Remove the caliper without disconnecting the brake hose from it and secure the caliper to the wire, avoiding tension on the hose.
2.5. Guide pin caps
6. Remove the pads from the caliper.
7. Thoroughly clean the caliper and mating surfaces of the pads. If there is a protective coating on the new pads, remove it. Use only methylated spirits for cleaning, do not blow out brake pad dust with compressed air.
8. Before installing the pads, press the piston into the brake wheel cylinder using a suitable tool (see illustration). At the same time, keep an eye on this. to prevent brake fluid from leaking out of the reservoir, pump it out if necessary.
2.8. Pressing the piston into the wheel cylinder
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9. Install the outer shoe into the anchor bracket and the inner shoe with the retaining spring into the piston. Install the caliper and secure it to the anchor bracket, tightening the guide pins to 30 Nm. When installing the caliper, make sure that the pads do not stick to it before it is in the correct installation position; do not damage the surface to be glued. Install the guide pin caps.
10. Insert the retaining spring into the caliper, connect the brake pad wear sensor wiring connector and install the wheels.
11. With the vehicle stationary, press the brake pedal hard several times until the pads reach their working position.
12. Correct the brake fluid level.
Removal and installation, repair of the caliper
13. Follow the steps described in paragraphs 2-4.
14. Connect a hose to the bleed nipple on the caliper, and lower the other end of this hose into a container to collect the brake fluid. Open the bleed nipple, press the brake pedal with the VAG1869/2 tool (or ask an assistant), close the bleed nipple and disconnect the hose from it.
15. Disconnect the brake hose from the caliper and remove the caps (see illustration 2.5) and turn out the guide pins located behind them.
16. Remove the caliper from the anchor bracket. If you need to repair the caliper (piston replacement) be guided by the support. illustration.
2.16. FN3 Caliper Parts 1. Cap; 2. Guide pin, 30 Nm; 3. Bearing sleeve, inserted into the caliper; 4. Cap; 5. Bleed nipple, before screwing in, apply a thin layer of G052 150A2 grease to the threads; 6. Support; 7. Anchor bracket; 8. Retaining spring, both ends are inserted into the holes in the caliper; 9. Cuff; 10. Piston, before installation, apply lithium grease G052 150A2 to it; 11. Dust cover
17. Follow the steps described in paragraphs 6-9.
18. Screw the brake hose into the caliper.
19. Remove tool VAG1869/2 or have an assistant release the brake pedal.
20. Insert the retaining spring into the caliper, connect the brake pad wear sensor wiring connector.
21. Bleed the brake hydraulic system (see Chapter 1) and install the wheels.
22. With the vehicle stationary, press the brake pedal hard several times until the pads reach their working position.
23. Correct the brake fluid level.
FS-III brake mechanisms
24. The parts of the front brake mechanism FS-III are shown in the illustration.
2.24. FS-III Front Brake Mechanism Parts 1. Bolt M 12x1.5x45, subject to replacement, 70 Nm, then tighten to an angle of 90°; 2. Steering knuckle with integrated anchor bracket; 3. ABS sensor, before installation, clean the walls of the mounting hole and apply G052 112A3 grease to them; 4. Bolt, 8 Nm; 5. Hub assembly, with built-in sensor rotor 3; 6. Brake mechanism shield; 7. Bolt, 12 Nm; 8. Brake disc, ventilated, replaceable on both sides at the same time; 9. Bolt, 4 Nm; 10. Brake pads with wear indicator, replaced in pairs, on both sides at the same time; 11. Brake pad wear sensor connector; 12. Support; 13. Guide pin, 30 Nm; 14. Cap; 15. Brake hose with connection and hollow bolt, 35 Nm; 16. Bolt, 15 Nm; 17. Bracket
Replacing the pads
25. Follow the steps in paragraphs 2 and 4-8.
26. Install the inner shoe (with the inscription "Kolbenseite" or "Pistonside", i.e. "piston side") and the outer shoe. The pads can be distinguished by the size of the tabs of the retaining springs: on the inner pad (1 in the illustration) they are larger than on the black outer one (2).
2.26. Inner (1) and outer (2) pads
27. Install the caliper with pads first on the lower side of the anchor bracket (see illustration). Secure the caliper to the anchor bracket by tightening the guide pins to 30 Nm. The caliper pin should be behind the guide on the anchor bracket. Install the guide pin caps.
2.27. Installing the caliper
28. Connect the brake pad wear sensor wiring connector and install the wheels.
29. With the vehicle stationary, press the brake pedal hard several times until the pads reach their working position.
30. Correct the brake fluid level.
Removal and installation, repair of the caliper
31. Jack up the car and place it on reliable supports. Remove the front wheel.
32. Disconnect the brake pad wear sensor wiring connector (see illustration 2.4).
33. Connect a hose to the bleed nipple on the caliper, and lower the other end of the hose into a container to collect the brake fluid. Open the bleed nipple, press the brake pedal with the VAG1869/2 tool (or ask an assistant), close the bleed nipple and disconnect the hose from it.
34. Disconnect the brake hose from the caliper and remove the caps (see illustration 2.5) and turn out the guide pins located behind them.
35. Remove the caliper from the anchor bracket. If you need to repair the caliper (piston replacement) be guided by the support. illustration.
2.35. FS-III Caliper Parts 1. Cap; 2. Bleed nipple, before screwing in, apply a thin layer of grease G 052 150 A2 to the thread; 3. Bearing sleeve, inserted into the caliper; 4. Guide pin, 30 Nm; 4. Cap; 6. Support; 7. Cuff, before installation apply a thin layer of lithium grease G 052 150 A2; 8. Piston, before installation apply a thin layer of lithium grease G 052 150 A2; 9. Dust cover
36. Perform the actions described in paragraphs 6-8 and 26-27.
37. Screw the brake hose into the caliper.
38. Remove tool VAG1869/2 or have an assistant release the brake pedal.
39. Perform the actions described in paragraphs 28-30.