Audi A6 2005 Workshop Manual
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Audi A6 2005 Workshop Manual

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Service
Workshop Manual
Audi A6 2005 ➤
Audi A6 Avant 2005 ➤
Brake system
Edition 04.2019
Service Department. Technical Information

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Summary of Contents for Audi A6 2005

  • Page 1 Service Workshop Manual Audi A6 2005 ➤ Audi A6 Avant 2005 ➤ Brake system Edition 04.2019 Service Department. Technical Information...
  • Page 2 In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed. All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2019 Audi AG, Ingolstadt A005A600220...

  • Page 3: Table Of Contents

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Contents 00 - Technical data ........... .
  • Page 4 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Removing and installing brake pads (1LT) ........
  • Page 5 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Rear brake calipers for electronic parking brake and handbrake (EPB) ....149 Servicing brake calipers .
  • Page 6 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Contents...

  • Page 7: Technical Data

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 00 – Technical data Technical data (ARL006362; Edition 04.2019) Allocation of PR number (factory code) to brake components The type of brake system installed in the vehicle is indicated by the corresponding PR number on the vehicle data sticker.
  • Page 8 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Note Maximum lateral run-out of steel brake disc: 0.06 mm ♦ Perform measurement with brake disc installed. ♦ Use dial gauge bracket VAS 6079/1 and dial gauge VAS 6079.
  • Page 9 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 ⇒ “4 Front brakes (steel version) - RS 6”, page 77 Brake discs Note When performing repair work on brakes, hairline cracks are ♦ often found on the friction surface of the brake discs. Hairline cracks up to a length of 10 mm do not present a technical problem and do not justify a renewal of brake discs.
  • Page 10 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Note Maximum lateral run-out of steel brake disc: 0.06 mm ♦ Perform measurement with brake disc installed. ♦ Use dial gauge bracket VAS 6079/1 and dial gauge VAS 6079.
  • Page 11 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Ceramic rear brakes Brake caliper, 1 pis‐ ∅ ∅ 45 Brake pad thick‐ 16.9 ness (including backplate) Pad wear limit (in‐ cluding backplate) Hairline cracks on the friction surfaces of ceramic brakes can be caused during manufacturing and therefore already appear to varying degrees when the brakes are new.

  • Page 12: Assessment Of Ceramic Brake Discs

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Assessment of ceramic brake discs 1 - Cooling channel lands 2 - Friction layer 3 - Carrier material Visible features of ceramic brake discs Checking area of bolted connection on friction ring and brake disc...

  • Page 13: Superficial Cracks In Cooling Channel Lands

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Due to the production process there already are relaxation cracks (varying degrees) on the friction surface of the brake disc when it is new. Note Relaxation cracks on a ceramic brake disc do not constitute a technical problem.

  • Page 14: Edge Fractures

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Ceramic brake discs must be renewed if there are cracks in the area of the bolted connection of the brake disc hub extending into the friction surface of the brake disc -arrows-.

  • Page 15: Cracks Extending Into Cooling Channels

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Cracks extending into cooling channels Always renew ceramic brake discs if there is any cracking ex‐ tending from the friction surface of the brake disc to the cooling channel or through the cooling channel.

  • Page 16: Assessing Degree Of Wear On Ceramic Brake Discs

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Assessing degree of wear on ceramic brake discs When minimum weight is stamped on hub of brake disc: WARNING The brake disc rotor and the brake disc hub are bolted together and must NOT be separated.
  • Page 17 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Note Depending on the version, the min‐ imum permissible weight for a used brake disc is stamped on the brake disc hub. The disc must be renewed when the weight of the disc is less than or equal to the indicated mini‐...
  • Page 18 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 ♦ 2. Wear assessment according to wear indicators 1. Wear assessment by checking thickness of brake disc ⇒ page 13 Thickness of brake discs in permissible range → brake disc OK...

  • Page 19: Wear Assessment By Checking Thickness Of Brake Disc

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 --------- ↓↓ ---------- 3. Weighing brake disc ⇒ page 15 ---------- Minimum weight not reached ---------- ↓↓ ---------- Brake disc OK ---------- Minimum weight reached ---------- ↓↓...

  • Page 20: Wear Assessment According To Wear Indicators

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Measurement of the brake disc thickness involves removing the brake discs. The minimum permissible thickness of the brake disc is engraved as “min.th.” on the brake disc hub.

  • Page 21: Wear Assessment By Weighing Brake Disc

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 The following two illustrations show brake discs on which the wear indicators are burnt out. In this case the brake disc must be re‐ newed.

  • Page 22: Wear Assessment Of Ceramic Brake Disc With Tester Vas 6813

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Note Depending on the version, the minimum permissible weight for a used brake disc is stamped on the brake disc hub. The disc must be renewed when the weight of the disc is less than or equal to the indicated minimum weight.
  • Page 23 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 You can identify the brake disc as follows: ♦ The wear indicators -arrow- on the friction surface of the brake disc are no longer visible ♦...
  • Page 24 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 3.5.1 Checking brake disc thickness The markings for measuring the degree of wear are spaced at intervals of 120°. Measure the brake disc thickness at these three points.
  • Page 25 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 3.5.2 Checking tester - VAS 6813- Before taking measurements, the tester - VAS 6813- must be checked using the measuring plate provided. Measuring plate: – Place tester in both openings -arrows- of measuring plate so that laser beam points downwards towards marking with af‐...
  • Page 26 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Tester - VAS 6813- : ♦ 1 ON/OFF switch ♦ 2 Button for taking measurement ♦ 3 Display for measurement ♦ 4 Laser beam for positioning ♦...
  • Page 27 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Move tester - VAS 6813- -1- along outer edge -2- until laser beam points exactly towards marking -D- on brake disc. – Measure wear at all three measuring points (1 to 3) on brake disc.
  • Page 28 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 3.5.4 Notes on ceramic brake disc wear limit Note The degree of wear is determined by measuring the brake disc ♦ thickness AND the wear value using the tester - VAS 6813- ;...

  • Page 29: Brake Test

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Brake test General notes The wheels are driven by the brake test rollers. During the test the gearbox must be in neutral on manual gear‐...

  • Page 30: Electromechanical Parking Brake On Brake Test Equipment

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Electromechanical parking brake on brake test equipment Test sequence: – Drive rear wheels of vehicle onto test rollers; do not switch off ignition. – The “test mode” (TÜV mode) is activated as soon as the rollers reach a speed between 4 km/h and 9 km/h.

  • Page 31: Brake Fluid

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Brake fluid General notes Brake fluid is hygroscopic; in other words it has the tendency to absorb water and moisture from the atmosphere. The boiling point decreases as the water content increases, which means that vapour bubbles can form when the brake fluid be‐...

  • Page 32: Anti-Lock Brake System

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 45 – Anti-lock brake system General information on the anti-lock brake system Notes for repair work on the ABS WARNING The anti-lock brake system is basically maintenance-free.
  • Page 33 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 ♦ Ensure that no brake fluid enters electrical connectors. 1. General information on the anti-lock brake system...

  • Page 34: Connecting Vehicle Diagnostic, Testing And Information System Vas 5051B Or Vas 5052 And Selecting Functions

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Connecting vehicle diagnostic, test‐ ing and information system - VAS 5051B- or -VAS 5052- and selecting functions Special tools and workshop equipment required ♦ Vehicle diagnostic, testing and information system - VAS...
  • Page 35 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Switch on the tester -arrow-. The tester is ready as soon as a picture of a car appears in the display. – Switch on ignition.

  • Page 36: Exploded View - Abs/Esp Components

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Exploded view - ABS/ESP components 1 - Traction control system warning lamp (00824-3424) - K86- ❑ Location: In the dash panel insert ❑ See ⇒ Owner's Manual for further information ❑...
  • Page 37 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 ♦ The warning lamp lights up while the vehicle is in motion. ❑ The vehicle can be decelerated with the standard brake system, i.e. without ABS.
  • Page 38 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 7 - Wheel bearing/wheel bearing unit ❑ The ABS sensor ring is installed in the wheel bearing 8 - Rear right/left speed sensor - G44/G46- ❑...
  • Page 39 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 14 - Brake light switch -F- and cruise control system brake pedal switch - F47- ❑ Removing and installing ⇒ page 50 ❑ Removing and installing brake light sensor (new version) ⇒...
  • Page 40 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Diagnostic connection Rep. gr.45 - Anti-lock brake system...

  • Page 41: Anti-Lock Brake System (Abs) Bosch 8.0

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Anti-lock brake system (ABS) Bosch 8.0 The vehicle is equipped with a diagonally split ABS brake system. The servo-assistance is pneumatic, supplied by the vacuum brake servo unit.

  • Page 42: Removing And Installing Hydraulic Control Unit

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 ⇒ page 40 9 - Buffer (2 x) 10 - Longitudinal member (body) 11 - Nut and washer assembly, 10 Nm 12 - Bracket for ESP 13 - Bolt with bonded rubber bush, tightening torque 10 Nm ❑...
  • Page 43 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 The hydraulic control unit is fitted on the left-hand side of the en‐ gine compartment. WARNING Do not bend the brake lines. – Note or request radio code on vehicles with coded radio if necessary.
  • Page 44 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Insert brake pedal actuator - V.A.G 1869/2- between brake pedal and driver's seat. Depress the brake pedal at least 60 mm. – Connect hose of bleeder bottle to bleeder screws of front left and rear left brake calipers and open bleeder screws.
  • Page 45 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Push retaining clip in -direction of arrow- and unplug connec‐ tor. – Remove bolts -1-. – Remove hydraulic control unit. Installing Install in reverse sequence, paying attention to the following: Note Do not remove sealing plugs from new hydraulic unit until cor‐...

  • Page 46: Removing And Installing Hydraulic Control Unit - S6 And Rs 6

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Press down red retainer catch. Tighten connections of all brake lines to hydraulic unit and brake master cylinder. – After tightening brake lines, tighten hydraulic unit -1-.
  • Page 47 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 ♦ Torque wrench - V.A.G 1331- ♦ Brake pedal actuator - V.A.G 1869/2- ♦ Sealing plugs (repair kit) - 1H0 698 311 A- Removing Fitting location: The hydraulic control unit is fitted on the left-hand side of the en‐...
  • Page 48 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Insert brake pedal actuator - V.A.G 1869/2- between brake pedal and driver's seat. Depress the brake pedal at least 60 mm. – Connect hose of bleeder bottle to bleeder screws of front left and rear left brake calipers and open bleeder screws.
  • Page 49 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Press red retainer catch upwards. Note Make sure brake fluid does not get into connector housing of ♦ control unit. This can result in corrosion of the contacts and failure of the system.
  • Page 50 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Connect pipes as previously marked: Note To make it easier to assemble the rear left and rear right brake lines, press the hydraulic control unit slightly forwards and tighten the bolts for the brake lines slightly.
  • Page 51 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – After tightening brake lines, tighten hydraulic unit -1-. – Remove brake pedal actuator - V.A.G 1869/2- . – Bleed brake system ⇒ page 154 –...

  • Page 52: Removing And Installing Parts Of Abs System On Front And Rear Axles

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Removing and installing parts of ABS system on front and rear axles Removing and installing parts of ABS system on front axle 1 - ABS speed sensor ❑...

  • Page 53: Removing And Installing Parts Of Abs System On Rear Axle

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 ♦ Torque wrench - V.A.G 1410- Removing – Raise vehicle. – Detach speed sensor wiring connector -1- from speed sensor. – Remove bolt -2- from wheel bearing housing.
  • Page 54 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 1 - Bolt ❑ Always renew if re‐ moved ⇒ Rep. gr. 42 ; Servicing rear drive shaft 2 - Wheel bearing/wheel bear‐ ing unit ❑...

  • Page 55: Removing And Installing Rear Wheel Speed Sensor

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Removing and installing rear wheel speed sensor Removing – Raise vehicle. – Detach speed sensor wiring connector -1- from speed sensor. – Remove bolt -2- from wheel bearing housing.

  • Page 56: Removing And Installing Parts Of Esp System

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Removing and installing parts of ESP system Removing and installing brake light switch Note The brake light switch must be removed in order to adjust it.

  • Page 57: Removing And Installing Brake Light Sensor

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Guide switch through mounting hole, press against brake ped‐ al and secure by turning 45° clockwise. – Plug in electrical connector. – Install driver's storage compartment ⇒ Rep. gr. 68 .

  • Page 58: Removing And Installing Esp Sensor Unit G419

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Pull brake light sensor out of its mounting -C-. Installing Note The plunger adjusts itself automatically when the brake light ♦ sensor is inserted.

  • Page 59: Removing And Installing Steering Angle Sender G85

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – -Arrow- points in direction of travel. – Remove the two securing bolts -arrows-. – Take out ESP sensor unit - G419- -1-. Installing WARNING Severe shocks or jolts can irreparably damage the ESP sensor unit - G419- .

  • Page 60: Removing And Installing Parking Brake Contact Switch F321

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Removing and installing parking brake contact switch - F321- Removing – Remove rear centre console. ⇒ Rep. gr. 68 – Remove Climatronic control unit - J255- . ⇒ Rep. gr. 87 –...
  • Page 61 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Open plastic housing cover. – Unplug electrical connector -1- on brake pressure sender. – Detach brake pressure sender from pipe connector and un‐ screw.

  • Page 62: Brakes - Mechanism

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 46 – Brakes - mechanism Front brakes FN3 (PR 1LT) ⇒ “1.1 Servicing front brakes (PR 1LT)”, page 56 Servicing front brakes (PR 1LT) Note Install all parts supplied in repair kit.
  • Page 63 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 ⇒ Item 4 (page 56) 9 - Bolt ❑ Clean ribs if using again ❑ 190 Nm 10 - Brake carrier ❑ Bolt to wheel bearing housing 11 - Brake pads ❑...

  • Page 64: Removing And Installing Brake Pads (1Lt)

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 13 - Brake disc ❑ Wear limit ⇒ page 1 ❑ Detach brake caliper prior to removing ❑ Thickness ⇒ page 1 ❑ Allocation ⇒ page 1 WARNING If one brake disc is dam‐...
  • Page 65 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Special tools and workshop equipment required ♦ Torque wrench - V.A.G 1331- ♦ Torque wrench - V.A.G 1410- ♦ Torque wrench - V.A.G 1332- ♦ Brake pedal actuator - V.A.G 1869/2- ♦...
  • Page 66 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Remove protective caps -arrows-. – On vehicles equipped with a brake pad wear indicator, unplug connector -1-. – Slightly lift up locating lug on lower part of connector -2- and turn 90°.
  • Page 67 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Press piston back. Use only methylated spirits to clean the brake caliper housing. Note Before inserting new brake pads, press piston back into cylinder with resetting appliance.

  • Page 68: Front Brakes Fnr G60 (Pr 1Lg/1Ld/1Lh/1Lv/1Zl)

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Front brakes FNR G60 (PR 1LG/1LD/ 1LH/1LV/1ZL) ⇒ “2.1 Servicing front brakes (PR 1LG/1LD/1LH/1LV/1ZL)”, page Servicing front brakes (PR 1LG/1LD/ 1LH/1LV/1ZL) Note Install all parts supplied in repair kit.
  • Page 69 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 housing 3 - Ribbed bolt, 196 Nm ❑ Clean ribs if using again ❑ M14 × 1.5 x 38 4 - Bearing bush ❑ Insert into brake caliper housing...

  • Page 70: Removing And Installing Brake Pads (Pr 1Lg/1Ld/1Lh/1Lv/1Zl)

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 8 - Wheel bolts ❑ Fit wheels ⇒ Wheels and tyres; Rep. gr. 44 . 9 - Bolt ❑ Tightening torque: 5 Nm 10 - Spring clip...
  • Page 71 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Special tools and workshop equipment required ♦ Torque wrench - V.A.G 1331- ♦ Torque wrench - V.A.G 1410- ♦ Torque wrench - V.A.G 1332- ♦ Brake pedal actuator - V.A.G 1869/2- ♦...
  • Page 72 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – To lever out retaining spring, insert screwdriver between re‐ taining spring and pad retaining spring. Note The spring is under tension; hold your hand over the spring to avoid risk of injury.
  • Page 73 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Remove protective caps -1-. – Unscrew and remove both guide pins from brake caliper. – Take off brake caliper housing and lay to one side so that the weight of the brake caliper does not stress or damage the brake hose.
  • Page 74 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Fit outer brake pad -2- in brake caliper. Note Fit brake pads into brake caliper and install assembly on brake carrier/brake disc. – Secure brake caliper housing to brake carrier with both guide pins (tighten to 30 Nm).
  • Page 75 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – ... then press on housing retaining spring at the bottom and at the same time press in pad retaining spring, as indicated by -arrows-.

  • Page 76: Front Brakes (Pr 1Lj/1Ll)

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Front brakes (PR 1LJ/1LL) ⇒ “3.1 Servicing front brakes (PR 1LJ/1LL)”, page 70 Servicing front brakes (PR 1LJ/1LL) Note Always install all parts supplied in repair kit.
  • Page 77 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 2 - Brake carrier ❑ Bolt to wheel bearing housing 3 - Ribbed bolt ❑ Tightening torque: 190 Nm ❑ Clean ribs if using again ❑...

  • Page 78: Removing And Installing Brake Pads (Pr 1Lj/1Ll)

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 8 - Wheel bolts ❑ Fitting wheels ⇒ Wheel/Tyre Guide 9 - Brake line connection to brake hose ❑ Tightening torque: 12 Nm 10 - Brake line ❑...
  • Page 79 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Remove wheels. – Secure brake disc with one wheel bolt see -arrow-. – Lever brake pad retaining spring out of brake caliper housing with a screwdriver and remove.
  • Page 80 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Detach brake line from bracket. – Remove protective caps -1-. – Unscrew and remove both guide pins from brake caliper. – Take off brake caliper housing and lay to one side so that the weight of the brake caliper does not stress or damage the brake hose.
  • Page 81 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Press back both pistons. Note Before inserting new brake pads, press pistons back into cylin‐ ders with resetting appliance. Before pressing the piston back, draw off brake fluid from the reservoir with a bleeder bottle.
  • Page 82 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Secure brake caliper housing to brake carrier with both guide pins (tighten to 30 Nm). – Fit both caps. – Make sure not to twist the brake hose when installing.

  • Page 83: Front Brakes (Steel Version) - Rs 6

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Front brakes (steel version) - RS 6 ⇒ “4.1 Servicing front brakes (steel version) - RS 6”, page 77 Servicing front brakes (steel version) -...

  • Page 84: Detaching And Attaching Front Brake Caliper - Rs 6

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 7 - Pad wear indicator wire ❑ On left and right brake caliper ❑ On inner brake pad 8 - Pad retaining pins ❑ Ensure correct installation position ❑...

  • Page 85: Renewing Front Brake Caliper (Rs 6)

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Remove bolts -1-. – Carefully detach brake caliper with brake pads installed. Note Brake caliper must not be dismantled. Do not loosen any bolts on the brake caliper.
  • Page 86 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Insert brake pedal actuator -V.A.G 1869/2- between brake pedal and driver's seat (depress brake pedal at least 60mm). This closes the valves in the brake master cylinder and stops the brake fluid reservoir from running empty.

  • Page 87: Removing And Installing Front Brake Pads - Rs 6

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Always use new bolts -1- ⇒ ETKA . – Secure brake caliper with new bolts -1- (196 Nm). – Connect brake line -11- to brake caliper and tighten connec‐...
  • Page 88 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Remove bolt -9-. – Pull retaining pin -3- out of brake caliper. – Press back brake pistons with brake pads installed using pis‐ ton resetting appliance - T10145- .
  • Page 89 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Press one pad retaining pin -8- out of brake caliper from out‐ side to inside with a punch. Note Make sure that paint on brake caliper is not scratched or dam‐...
  • Page 90 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Note The damper weights point towards the brake disc. – Insert pad retaining spring -10-. Note Ensure that pad retaining spring is seated correctly. – Push one pad retaining pin -8- through hole in brake caliper from inside to outside.

  • Page 91: Detaching And Attaching Front Brake Disc - Rs 6

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Slide retaining pin -3- through brake caliper from outside to inside. Note Make sure that the projections on the retaining pin and on the brake caliper coincide.

  • Page 92: Renewing Front Brake Disc - Rs 6

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Do not leave brake caliper and brake carrier hanging from brake hose but secure them to bodywork using a suitable cable tie or wire. Take care that brake hose is not damaged by weight of brake components.
  • Page 93 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Do not leave brake caliper hanging from brake hose but secure it to bodywork using a suitable cable tie or wire. Take care that brake hose is not damaged by weight of brake components.

  • Page 94: Ceramic Front Brakes

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Ceramic front brakes ⇒ “5.1 Servicing ceramic front brakes”, page 88 WARNING The brake disc rotor and the brake disc hub are bolted together and must NOT be separated. DO NOT slacken the bolted con‐...
  • Page 95 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 1 - Brake caliper Illustration: Front left brake cal‐ iper Note Brake caliper must not be disman‐ tled. Do not loosen any bolts on the brake caliper.

  • Page 96: Detaching And Attaching Front Brake Caliper (Ceramic Brakes)

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 14 - Securing clip Note Lock each retaining pin with a se‐ curing clip 15 - Pin for pad retaining spring ❑ Ensure correct installation position ❑...
  • Page 97 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Caution On vehicles with ceramic brakes the wheel must not be allowed to drop onto the brake disc. This would cause irreparable dam‐ age to the disc. Screw two assembly pins (from vehicle tool kit) into the wheel bolt holes when removing and fitting a wheel.

  • Page 98: Renewing Front Brake Caliper (Ceramic Brakes)

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Always use new bolts -1- ⇒ ETKA . – Secure brake caliper with new bolts -3- (196 Nm). – Clip brake hose into retainer on wheel bearing housing.
  • Page 99 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Insert brake pedal actuator -V.A.G 1869/2- between brake pedal and driver's seat (depress brake pedal at least 60mm). This closes the valves in the brake master cylinder and stops the brake fluid reservoir from running empty.
  • Page 100 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Remove bolts -3-. – Remove brake caliper from vehicle. Installing New-generation brake pads Make sure the brake pads are installed in the correct position. The brake pad with wear indicator is located on the inside.

  • Page 101: Removing And Installing Front Brake Pads (Ceramic Brakes)

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Make sure the brake pads are installed in the correct position. The brake pad with wear indicator is located on the inside. The cham‐ fered side of the brake pad -arrow- faces downwards when in‐...
  • Page 102 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Caution On vehicles with ceramic brakes the wheel must not be allowed to drop onto the brake disc. This would cause irreparable dam‐ age to the disc. Screw two assembly pins (from vehicle tool kit) into the wheel bolt holes when removing and fitting a wheel.
  • Page 103 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Do not remove the brake caliper to remove the brake pads. Illustration: Front left brake caliper – Unplug electrical connector for pad wear indicator wire -12-.
  • Page 104 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Make sure the brake pads are installed in the correct position. The brake pad with wear indicator is located on the inside. The cham‐ fered side of the brake pad -arrow- faces downwards when in‐...
  • Page 105 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Insert pad retaining spring -17- into brake caliper and hold in position. Ensure correct installation position – Slide pad retaining pin -16- through brake caliper and brake pads from inside to outside as far as stop.

  • Page 106: Detaching And Attaching Front Brake Disc (Ceramic Brakes)

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Note The pad retaining spring must be under tension. The pad retaining spring -17- must be seated underneath the pad retaining pin -16- and above the pin for the pad retaining spring -15-.

  • Page 107: Renewing Front Brake Disc (Ceramic Brakes)

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Do not leave brake caliper and brake carrier hanging from brake hose but secure them to bodywork using a suitable cable tie or wire. Take care that brake hose is not damaged by weight of brake components.
  • Page 108 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 WARNING If one brake disc is damaged or worn, the other discs must also be checked for damage and wear. Removing – Raise vehicle. – Remove wheels.
  • Page 109 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Screw in locating bolt -8- and tighten to 10 Nm. – Attach brake caliper ⇒ page 90 – Install brake pads ⇒ page 95 New-generation brake pads Make sure the brake pads are installed in the correct position.

  • Page 110: Rear Brakes, Electronic Parking Brake And Handbrake (Epb)

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Rear brakes, electronic parking brake and handbrake (EPB) ⇒ “6.1 Servicing rear brakes (including ceramic brakes) - all mod‐ els”, page 104 Servicing rear brakes (including ceramic...
  • Page 111 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 1 - Self-locking bolt (Torx 30), tightening torque 12 Nm 2 - Actuator motor for electron‐ ic parking brake and hand‐ brake ❑ Removing and installing control unit for electron‐...
  • Page 112 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 installing 7 - Brake caliper housing ❑ Do not disconnect brake hose when changing brake pads ❑ Servicing brake caliper ⇒ page 150 ❑ The brake carrier can be mounted together with the brake caliper 8 - Brake carrier with guide pins and protective caps ❑...

  • Page 113: Removing And Installing Brake Pads

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Removing and installing brake pads Steel version brakes: When renewing the brake pads, also check the brake disc for wear. Refer to wear limit for brake disc ⇒...
  • Page 114 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Special tools and workshop equipment required ♦ Piston resetting appliance - T10145- Removing Note Mark brake pads when removing them if they are to be rein‐...
  • Page 115 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Indicated on display of VAS 5051: – Select function “53 - Parking brake”. – Select function “04 - Basic setting”. Indicated on display of VAS 5051: ♦...
  • Page 116 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 ♦ Piston resetting appliance - T10145- Note On vehicles with a 16" brake system, the brake carrier must ♦ be removed prior to removing the brake discs Check brake discs and renew if necessary.
  • Page 117 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Fit brake pads. – Ensure that the brake pads are located correctly in the pad retainers -arrows-. Note The next work step only applies to vehicles on which the brake carrier needed to be removed.
  • Page 118 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Indicated on display of VAS 5051: ♦ The prompt to enter a display group appears in display zone -1-. ♦ Display zone -2- shows a keypad.

  • Page 119: Exploded View - Brake Pedal, Left-Hand Drive Vehicles With Manual Gearbox

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Exploded view - brake pedal, left- hand drive vehicles with manual gearbox WARNING The brake pedal travel must not be restricted by additional floor coverings.

  • Page 120: Removing And Installing Brake Pedal - Left-Hand Drive Vehicles

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 15 - Retaining clip (spring steel) ⇒ ETKA 16 - Hexagon socket head flange bolt, 10 Nm 17 - Bracket for clutch sensor 18 - Pin...

  • Page 121: Exploded View - Brake Pedal, Left-Hand Drive Vehicles With Automatic Gearbox

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Exploded view - brake pedal, left- hand drive vehicles with automatic gearbox WARNING The brake pedal travel must not be restricted by additional floor coverings.

  • Page 122: Exploded View - Brake Pedal, Right-Hand Drive Vehicles

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Exploded view - brake pedal, right- hand drive vehicles WARNING The brake pedal travel must not be restricted by additional floor coverings. ♦ Lubricate all bearings and contact surfaces with grease - G 000 450 02- .

  • Page 123: Removing And Installing Brake Pedal - Right-Hand Drive Vehicles

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Installation of bracket for brake light switch – Socket head bolt -1-, tightening torque: 9 Nm – Item -2-: Bracket – Item -3-: Pedal bracket Installation of brake pedal (automatic gearbox) –...

  • Page 124: Separating Brake Pedal From Brake Servo

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Pull out pin -3-. – Take out brake pedal. Installing Install in reverse sequence, paying attention to the following: Attaching brake pedal to brake servo –...
  • Page 125 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – First press brake pedal in direction of brake servo and hold. 1 - Brake pedal 2 - Push rod 3 - Retaining lugs – Insert release tool - T10159- and pull towards driver's seat, at the same time holding brake pedal in position (the pedal must not move towards the rear).

  • Page 126: Removing And Installing Mounting Bracket

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Removing and installing mounting bracket 10.1 Removing and installing mounting bracket Special tools and workshop equipment required ♦ Torque wrench - V.A.G 1410- ♦ Torque wrench - V.A.G 1331- Removing –...
  • Page 127 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Separate brake pedal from brake servo ⇒ page 118 – Unplug connection -1- for clutch pedal switch - F36- – Unplug connection -1- from clutch pedal switch - F194- –...
  • Page 128 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Allocation of multi-point socket head bolts ⇒ ETKA , tightening torque: 25 Nm. – Take out body brace -2-. Note Do not remove brake fluid reservoir.
  • Page 129 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Unscrew hexagon socket head bolt -1-, tightening torque 25 Nm. – Remove mounting bracket. Remove accelerator pedal. Installing Install in reverse sequence, paying attention to the following: –...

  • Page 130: Overview Of Components - Electronic Parking Brake And Handbrake (Epb)

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Overview of components - electronic parking brake and handbrake (EPB) 1 - Parking brake contact switch - F321- ❑ Pull switch ⇒ to apply brake ❑...

  • Page 131: Removing And Installing Electric Park And Handbrake Control Unit J540

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 ed off. ❑ If the parking brake is applied with ignition switched off, the lamp lights up for approx. 30 seconds. ❑ The lamp should go out when the parking brake is released.

  • Page 132: Removing And Installing Actuator Motor For Electronic Parking Brake And Handbrake

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Unscrew nuts -1-; tightening torque 10 Nm. – Remove EPB control unit with connection -item 2-. – Move locking slide -a- in direction of arrow -b- and unplug connector.
  • Page 133 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Remove wheels. Note Ignition must be switched off at least 30 sec. before unplugging ♦ connector. Clean whole area around connector and actuator motor/brake ♦...
  • Page 134 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Turn adjusting screw on brake caliper back slightly. Note This makes it easier to install the actuator motor. – Fit actuator motor as shown in illustration (item -1-).

  • Page 135: Brakes - Hydraulics

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 47 – Brakes - hydraulics Pressurised leak test Pressurised leak test Special tools and workshop equipment required ♦ Tester for brake pressure regulator - V.A.G 1310A-...

  • Page 136: Brake Caliper Fn3

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Brake caliper FN3 Servicing brake calipers Note Install complete repair kit when servicing. ♦ New brake calipers are filled with brake fluid and are pre-bled.

  • Page 137: Removing And Installing Piston For Front Brake Caliper

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Removing and installing piston for front brake caliper Special tools and workshop equipment required ♦ Assembly paste - G 052 150 A2- ♦ Removal tool - T 40338- ♦...
  • Page 138 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Removing – Force piston out of brake caliper housing using compressed air. Note Place a piece of wood in the recess to prevent damaging the pis‐...
  • Page 139 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Using removal wedge - 3409- , insert inner sealing lip into groove of cylinder. Note When doing this hold piston in front of caliper housing.

  • Page 140: Brake Caliper Fnr G60

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Brake caliper FNR G60 Servicing brake calipers Note Install complete repair kit when servicing. ♦ Apply a thin coat of assembly paste - G 052 150 A2- to brake ♦...

  • Page 141: Removing And Installing Piston For Front Brake Caliper

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Removing and installing piston for front brake caliper Special tools and workshop equipment required ♦ Torque wrench - V.A.G 1331- ♦ Torque wrench - V.A.G 1332- ♦...
  • Page 142 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 ♦ Carefully lever protective cap -1- and seal out of brake caliper with gentle movements using removal tool - T 40338- -2-; take care not to damage groove for protective cap in brake caliper.
  • Page 143 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Press in protective cap with special tool -1- and -2-. – -Item 1-: Assembly tool for protective caps - T10146/1- – -Item 2-: Piston resetting appliance - T10145- Use jaw protectors –...

  • Page 144: Brake Calipers 2Fnr 42 Al

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Brake calipers 2FNR 42 AL Servicing brake calipers Note Install complete repair kit when servicing. ♦ Apply a thin coat of assembly paste to brake cylinders, pistons ♦...

  • Page 145: Removing And Installing Piston For Front Brake Caliper

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Removing and installing piston for front brake caliper Special tools and workshop equipment required ♦ Removal wedge - 3409- ♦ Removal tool - T 40338- ♦...
  • Page 146 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Removing – Force piston out of brake caliper housing using compressed air. – Item -1-: Piston resetting appliance -T10145- Note Place a piece of wood in the recess to prevent damaging the pis‐...
  • Page 147 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – At this stage it should not be possible to remove the protective cap from the brake caliper housing by hand. – Apply a small amount of assembly paste to piston and seal before inserting.

  • Page 148: Servicing Brake Calipers (Steel Version) - Rs 6

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Servicing brake calipers (steel ver‐ sion) - RS 6 Note Install complete repair kit when servicing. ♦ Apply a thin coat of assembly paste to brake cylinders, pistons ♦...
  • Page 149 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 ♦ Carefully lever protective cap -1- and seal out of brake caliper with gentle movements using removal tool - T 40338- -2-; take care not to damage groove for protective cap in brake caliper.
  • Page 150 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Take out seal. – Item -1-: Piston resetting appliance -T10145- Note When removing ensure that the bore of the cylinder is not dam‐ aged.
  • Page 151 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Press piston into brake caliper housing by hand. Note The inner sealing lip on the protective cap will then locate in the piston groove.

  • Page 152: Servicing Front Brake Calipers (Ceramic Brakes) - Rs 6

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Servicing front brake calipers (ce‐ ramic brakes) - RS 6 Note Install complete repair kit when servicing. ♦ Apply a thin coat of assembly paste to brake cylinders, pistons ♦...

  • Page 153: Removing And Installing Pistons For Front Brake Caliper (Ceramic Brakes)

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Removing and installing pistons for front brake caliper (ceramic brakes) Special tools and workshop equipment required ♦ Assembly paste - G 052 150 A2- ♦ Removal tool - T 40338- ♦...
  • Page 154 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Carefully lever protective cap -1- and seal out of brake caliper with gentle movements using removal tool - T 40338- -2-; take care not to damage groove for protective cap in brake caliper.

  • Page 155: Rear Brake Calipers For Electronic Parking Brake And Handbrake (Epb)

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Rear brake calipers for electronic parking brake and handbrake (EPB) Servicing brake calipers Note When carrying out repairs install all parts supplied in repair kit.

  • Page 156: Removing And Installing Piston For Rear Brake Caliper

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 ❑ Push outer sealing lip onto piston Removing and installing piston for rear brake caliper Special tools and workshop equipment required ♦ Torque wrench - V.A.G 1331- ♦...
  • Page 157 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 ♦ Carefully lever protective cap -1- and seal out of brake caliper with gentle movements using removal tool - T 40338- -2-; take care not to damage groove for protective cap in brake caliper.
  • Page 158 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Fit the new seal in the brake caliper. – Fit the new protective cap onto the brake piston as shown in the illustration. – Screw in compressor nut to dimension -a- 15 mm.
  • Page 159 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Press brake piston onto stop in brake caliper after guiding it onto the compressor nut. Note Make sure not to damage the compressor nut.

  • Page 160: Bleeding Brake System

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Bleeding brake system ⇒ “8.1 Bleeding hydraulic system with brake filling and bleeding equipment”, page 155 ⇒ “8.2 Bleeding hydraulic system without brake filling and bleed‐...

  • Page 161: Bleeding Hydraulic System With Brake Filling And Bleeding Equipment

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Bleeding hydraulic system with brake filling and bleeding equipment Note A pressure of 2 bar is required for bleeding the hydraulic unit. ♦ For this reason it is important to always check the pressure setting on the bleeder unit.
  • Page 162 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Observe instructions given in operating manual for -VAS 5234- or brake filling and bleeding equipment - VAS 6860- . Procedure – Fill brake fluid into brake fluid reservoir up to “max” marking.

  • Page 163: Bleeding Hydraulic System Without Brake Filling And Bleeding Equipment

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Fill brake fluid into brake fluid reservoir up to “max” marking. – Close reservoir. – Start engine and check brake pedal travel and brake pedal pressure.
  • Page 164 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 ♦ Brake pipe bleeding wrench - VAS 5519- Procedure – Fill brake fluid into brake fluid reservoir up to “max” marking. – Close reservoir. WARNING ♦...

  • Page 165: Changing Brake Fluid

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Remove protective cap -1- from bleeder screw on relevant brake caliper and fit hose from reservoir onto bleeder screw. Bleeding sequence Front left brake caliper...

  • Page 166: Exploded View - Brake Servo / Brake Master Cylinder

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Exploded view - brake servo / brake master cylinder Note Brake master cylinders can no longer be dismantled, i.e. there ♦ is no provision for servicing.
  • Page 167 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 ⇒ page 165 6 - Hexagon socket head flange bolt, 25 Nm 7 - Mounting bracket for pedal cluster ❑ Removing and installing ⇒ page 120...

  • Page 168: Removing And Installing Brake Master Cylinder

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Removing and installing brake mas‐ ter cylinder 10.1 Removing and installing brake master cylinder Special tools and workshop equipment required ♦ Brake filling and bleeding equipment - VAS 5234- or ♦...
  • Page 169 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Remove multi-point socket head bolts -1- and -3-, tightening torque 25 Nm. – Take out body brace -2-. – Open brake fluid reservoir. – As protection against escaping brake fluid, place a sufficient number of lint-free cloths in area beneath brake master cylin‐...
  • Page 170 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Disconnect brake lines -1- and -2- from brake master cylinder and hydraulic unit and remove. – Unscrew securing bolts for brake master cylinder -1-.

  • Page 171: Brake Servo

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Brake servo 11.1 Removing and installing brake servo Special tools and workshop equipment required ♦ Brake filling and bleeding equipment - VAS 5234- or ♦ Brake filling and bleeding equipment - V.A.G 1869- ♦...
  • Page 172 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Detach plenum chamber cover. – Remove multi-point socket head bolts -1- and -3-, tightening torque 25 Nm. – Take out body brace -2-. – Remove wiper arms ⇒ Rep. gr. 92 .
  • Page 173 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Unplug connector -2-. Note Protect the plenum chamber against any brake fluid which es‐ capes. – Disconnect brake line – To remove reservoir, press down locking lug and at the same time pull brake fluid reservoir out of sealing plugs.

  • Page 174: Vacuum Pumps For Brake Servo

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Vacuum pumps for brake servo Removing and installing vacuum pump (2.0 ltr. petrol engine) ⇒ page 170 Removing and installing vacuum pump (2.4 ltr. petrol engine) ⇒...

  • Page 175: Removing And Installing Vacuum Pump

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 1 - Bolt ❑ 9 Nm 2 - Vacuum pump ❑ Removing and installing ⇒ page 169 3 - Vacuum hose ❑ Secure with hose clips (same as original equip‐...

  • Page 176: Removing And Installing Vacuum Pump - Vehicles With 2.0 Ltr. Petrol Engine

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Unscrew bolt -1- and detach vacuum hose with connection at vacuum pump. – Remove bolts -arrows- and take off vacuum pump. Installing Install in reverse sequence, paying attention to the following: Note Renew O-rings.
  • Page 177 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Carefully pull engine cover panels away from retaining pins, one after the other. The vacuum pump is located in the rear of the engine compart‐...
  • Page 178 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Remove all bolts -arrows- from sealing flange of vacuum pump. Note Do not disconnect vacuum hose from vacuum line at plenum chamber partition panel.

  • Page 179: Removing And Installing Vacuum Pump - Vehicles With 2.4 Ltr. Petrol Engine

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 12.4 Removing and installing vacuum pump - vehicles with 2.4 ltr. petrol engine The vacuum pump is fitted at the front left of the engine.

  • Page 180: Removing And Installing Vacuum Pump - Vehicles With 2.8 Ltr. Petrol Engine

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 12.5 Removing and installing vacuum pump - vehicles with 2.8 ltr. petrol engine The vacuum pump is fitted at the front left of the engine.

  • Page 181: Removing And Installing Vacuum Pump - Vehicles With 3.0 Ltr. Petrol Engine

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 12.6 Removing and installing vacuum pump - vehicles with 3.0 ltr. petrol engine The vacuum pump is fitted at the front left of the engine.

  • Page 182: Removing And Installing Vacuum Pump - Vehicles With 3.2 Ltr. Petrol Engine

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Close hose clip using suitable pliers. – Install and secure radiator fan control unit. 12.7 Removing and installing vacuum pump - vehicles with 3.2 ltr. petrol engine The vacuum pump is fitted at the front left of the engine.

  • Page 183: Exploded View - Vacuum Pump, Rs 6

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 12.8 Exploded view - vacuum pump, RS 6 The RS 6 model has a mechanically driven vacuum pump. It is also provided with a vacuum connection to the intake manifold for the critical idling speed.

  • Page 184: Removing And Installing Vacuum Pump - Rs 6

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 12.9 Removing and installing vacuum pump - RS 6 Removing • Engine/gearbox assembly removed ⇒ Rep. gr. 10 . – Remove front exhaust pipe (right-side) with catalytic convert‐...

  • Page 185: Removing And Installing Vacuum Pump - Vehicles With Diesel Engine

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 12.10 Removing and installing vacuum pump - vehicles with diesel engine Removing The vacuum pump is located in the rear of the engine compart‐ ment -arrow-, as seen in the direction of travel.
  • Page 186 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Detach vacuum hose -1- from vacuum pump. – Remove all bolts -arrows- from sealing flange of vacuum pump. – Pull vacuum pump out of its mounting.

  • Page 187: Removing And Installing Vacuum Pump - Vehicles With 2.7 Ltr. Tdi And 3.0 Ltr. Tdi Diesel Engine

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 12.11 Removing and installing vacuum pump - vehicles with 2.7 ltr. TDI and 3.0 ltr. TDI diesel engine Removing The vacuum pump is fitted at the rear of the right cylinder bank -arrow-.
  • Page 188 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Remove all bolts -arrows- from sealing flange of vacuum pump. – Pull vacuum pump out of its mounting. – Disconnect vacuum line from vacuum pump after removing pump.

  • Page 189: Checking Electric Vacuum Pump For Brakes V192

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Checking electric vacuum pump for brakes - V192 - Description and function The vacuum pump is capable of self-diagnosis. Recognised faults are stored in the engine control unit.
  • Page 190 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Switch on the tester -arrow-. The tester may need up to 3 minutes before it is ready for oper‐ ation. – Switch on ignition.

  • Page 191: Exploded View - Electric Vacuum Pump For Brakes V192

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 The following information will appear at the bottom of the display: Basic setting Not operated Pump off xxx mbar Syst.n.OK – Follow “Guided Fault Finding” procedure using vehicle diag‐...
  • Page 192 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 ♦ Torque wrench - V.A.G 1410- ♦ Torque wrench - V.A.G 1331- The vacuum pump is not intended to be serviced. If problems oc‐ cur, trace the fault by means of a function test and/or pressurised leak test.
  • Page 193 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Unplug electrical connector -1-. – Detach vacuum hose from vacuum pump. – Lift out electric vacuum pump. Removing bracket for electric vacuum pump Note The vacuum pump must be unclipped from the retainer before removing the bracket.

  • Page 194: Removing And Installing Electric Vacuum Pump - S6

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Remove bolt -1-. Installing Installation is carried out in reverse sequence. Note Use new clip when fitting vacuum line. 13.3 Removing and installing electric vacuum pump - S6 The S6 model has an electrically driven vacuum pump.

  • Page 195: Brake Servo Pressure Sensor G294

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Unplug electrical connector -1-. – Lift out electric vacuum pump. Installing Installation is carried out in reverse sequence. – Slide vacuum hose onto connection of vacuum pump with new hose clip.

  • Page 196: Checking Non-Return Valve

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Release clip using pliers -1-. – Carefully lever off brake servo pressure sensor - G294- . Installing Installation is carried out in reverse sequence.

  • Page 197: Brake Hoses And Brake Lines

    Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 Brake hoses and brake lines 14.1 Routing of brake hoses/lines Replacement brake hoses and brake lines are supplied as spare parts ready to be installed.
  • Page 198 Audi A6 2005 ➤ , Audi A6 Avant 2005 ➤ Brake system - Edition 04.2019 – Item -3-: Brake line, tightening torque: 12 Nm Brake line connection in wheel housing at front wheels – Item -1-: Brake hose bracket – Item -2- Brake line, tightening torque: 12 Nm Routing of brake lines at rear wheels –...

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A6 avant 2005

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