00 - GENERAL, TECHNICAL DATA
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1 00 - GENERAL, TECHNICAL DATA BRAKES BRAKES Brake System - A8 & S8 Brake system Dual-circuit brake system with diagonal distribution with ABS, EBV, EDL, ASR, ESP, ECD and EPB Master brake cylinder Dia. mm Brake booster, pneumatic Dia. in inches Tandem Assist factor 7 Front brakes Brake caliper FNR G60 (16)FNR G60 (16) FNR 42 AL FNR 42 AL FNR 42 AL (17) (17) (18) Productionrelevant 1LG 1LG 1LL 1LM 1LJ no. (Pr. no.) Brake disc dia. mm ventilated Brake disc, mm thickness Brake disc, mm wear limit Brake caliper, dia. mm x 42 2 x 42 2 x 42 piston Brake pad mm thickness Brake pad, wear limit mm Brake caliper Production-relevant no. (Pr. no.) Brake disc ventilated Brake disc, thickness Brake disc, wear limit Brake caliper, 6 piston monoblock Ceramic front brakes CISC Brembo M6 Al 1LW dia. 385 mm 36 mm The minimum measurement and minimum weight of the brake disc is stamped on the brake disc socket as the wear limit. every 2 x 32/ 36/ 38 mm
2 Brake pad thickness Minimum pad thickness with backing plate and dampening sheet 20.4 mm 9.5 mm Brake discs NOTE: Productionrelevant no. (Pr. no.) Brake disc, ventilated Brake disc, thickness Brake disc, wear limit Brake caliper, piston Brake pad thickness Brake pad, wear limit Hairline cracks on brake disc friction surfaces are often observed during brake repairs. Hairline cracks up to 10 mm long are not a technical flaw and are not cause for brake disc replacement. Brake discs with friction surfaces that have worn through should be replaced. Rear brakes 1KE (16) 1KW (17) 1KY (18) 1KZ (18) dia. mm mm mm dia. mm mm mm Brake caliper Production-relevant no. (Pr. no.) Brake disc ventilated Brake disc, thickness Brake disc, wear limit Brake caliper, 1 pistons Brake pad thickness Remaining pad strength with backing plate and dampening sheet Ceramic - rear brakes Pagid P40-3V 1KU dia. 356 mm 28 mm The minimum measurement and minimum weight of the brake disc is stamped on the brake disc socket as the wear limit. dia. 45 mm 16.5 mm 9.0 mm BRAKE FLUID
3 General information Brake fluid is hygroscopic, i.e. it has the capability to absorb water and moisture from the air. Fig. 1: Brake Fluid Graph If water has been absorbed, the boiling point will drop, i.e., during high braking temperatures the brake fluid may develop steam bubbles and cause the brakes to fail. Over time, brake fluid will darken in color. Dark-colored brake fluid does not specify anything about its quality. The coloring occurs through chemical reactions and can occur after a short time (several weeks), especially in vehicles with ABS. CAUTION: The rubber components of the brake system (boots, seals) do not tolerate mineral oil, gasoline, and cleaning agents! Even the smallest amount on a seal or boot can cause the part to change and thereby affect the function of the brake system. The results of an unclean brake system first show themselves months later, causing increased repair costs, especially on vehicles with ABS. Fig. 2: Sleeve Original Size And Swollen As A Result Of Contact With Mineral Oil
4 A = Boot - Original size B = Boot - Swollen through contact with mineral oil It is implied by the previously mentioned points that: Keep containers of brake fluid closed securely. This is to make sure that no oil, dirt or cleaning materials and no air moisture can enter the container. Store containers of brake fluid away from oil (even hydraulic oil) and cleaning fluids to prevent an accidental mixing of both fluids or even filling the brake system with the wrong fluid ANTI-LOCK BRAKE SYSTEM NOTES FOR REPAIR WORK ON ABS CAUTION: The Anti-lock brake system is generally maintenance-free. Testing, assembly, and repair work may only be performed by qualified personnel. By not observing the points described in the article, the system can be damaged and vehicle safety could be compromised. Before performing repair work on Anti-lock brake system, determine cause of the malfunction using On- Board Diagnostics (OBD). If you install a new hydraulic control unit, you must check its coding. VAS 5051 Vehicle Diagnostic, Testing and Information System Switch ignition off before installation work. On vehicles with coded radio, determine code and disconnect battery Ground (GND) strap. When working with brake fluid, observe relevant safety precautions and notes --> Brake fluid. With all work that requires hydraulic system to be opened, brake system should be bled (e.g. with Brake Filler/Bleeder Unit VAS 5234 ) --> Bleeding procedure for vehicles with Electronic Stabilization Program (ESP). High and low pressure testing should also be performed on the brake system --> High and low pressure testing During final road test, ensure that an ABS controlled braking is performed at least one time (pulsing must be felt in brake pedal). See Vehicle Diagnosis, Testing and Information System VAS 5051 Absolute cleanliness is required when working on the Anti-lock brake system, it is not permitted to use any products which contain mineral oil, such as oils, greases etc. Thoroughly clean all unions and adjacent areas before loosening. Do not use aggressive cleaning agents such as brake cleaner, fuel, thinners or similar chemicals. Place parts that have been removed on a clean surface and cover.
5 Carefully cover over opened components or seals, if repairs are not carried out immediately. (Sealing plugs, use repair kit 1 H A) Only use lint-free cloths. Only unpack replacement parts immediately prior to installation. Only use genuine packed parts. Do not work with compressed air and do not move vehicle while system is open. Make sure that no brake fluid enters plug connectors. CONNECTING VAS 5051 AND SELECTING FUNCTIONS Connecting VAS 5051 and selecting functions Special tools, testers and auxiliary items required Vehicle Diagnosis, Testing and Information System VAS 5051 Fig. 3: VAS 5051 Vehicle Diagnosis, Testing and Information System Diagnostic cable, 3 m with voltage supply VAS CAUTION: During a test drive, the testing and measuring equipment must always be secured on the back seat. These devices may be operated only by a passenger during a test drive.
6 Fig. 4: Connecting Data Link Connector (DLC) Connect VAS 50515a diagnostic cable connector to Data Link Connector (DLC). Fig. 5: VAS 5051 & On Switch Switch on tester - arrow -. The tester is ready for operation when it displays the image (photo) of a vehicle. Switch on ignition. Touch field / button on screen: Guided Fault Finding. Select one after another: Brand
7 Type Model year Version Engine code Confirm entered data. Wait until tester has checked all control modules installed in the vehicle. Press Goto button and select "Function/Component Selection" function. Select on display "Suspension" Select on display "Brake system" Select "01-On Board Diagnostic (OBD) capable system..." indicated on display. Select on display "Anti-lock brake system...". Select on display "Function". Now, all possible functions of Anti-lock Brake System (ABS) installed in vehicle are displayed. Select desired function on display. ELECTRONIC STABILIZATION PROGRAM, BOSCH 5.7 ESP, Bosch 5.7, component overview
8 Fig. 6: ESP, Bosch 5.7, Component Overview 1 - ABS Hydraulic Unit N55 with ABS Control Module J104 The hydraulic control unit is comprised of the hydraulic unit and control module. Do not disconnect connector (42-pin) before successfully completing self-diagnosis. Switch ignition off before separating connector. Component location: On hydraulic unit in engine compartment, left Removing and installing --> Hydraulic unit, removing and installing 2 - Brake Pressure Sensor 1 G201 Attached to hydraulic subframe Removing and installing --> Brake Pressure Sensor 1 G201, removing and installing
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