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Home >> Audi >> 2008 >> A8L Quattro Sedan (4E8) V8-4.2L (BVJ) >> Repair and Diagnosis >> Brakes and Traction Control >> Disc Brake System >> Brake Caliper >> Service and Repair >> Removal and Replacement >> Brake Caliper Piston >> Ceramic CSIC

Ceramic CSIC






Brake Caliper Piston

Special tools, testers and auxiliary items required

• (V.A.G 1331) Torque wrench

• (V.A.G 1332) Torque wrench

• (T10145) Piston resetting tool

• Trim Removal Wedge (3409)

• (VAS 5051) Vehicle diagnosis, testing and information system

Removing

- Raise vehicle.

- Remove wheels.

- With ignition off, connect Vehicle Diagnosis, Testing and Information System (VAS 5051) with diagnostic cable (VAS 5051/1) to 16-pin vehicle Data Link Connector (DLC) and select parking brake in OBD using "Address word" 53.





• Ignition on

• Release parking brake

• Coding check and reported if necessary.

• DTC memory interrogated, errors shown corrected and DTC memory erased.

Shown on VAS 5051 display:





- Select function "04 - Basic setting".

Shown on VAS 5051 display:





• The request to enter a display group number appears in display field - 1 -.

• An entry keypad is shown in display field - 2 -.

- Using entry keypad in display field - 2 -, enter " 7" for "Display group number 007" and confirm by pressing Q button (brake opens completely).

- Remove attachment bolts from brake caliper housing, to do so counter-hold guide pins.





• Actuator or brake system connector must not be disconnected.

- Slide connector out of bracket





- Remove brake caliper sideways

- Remove brake pads

- Remove guide clamps => OBD; "Address word" 53 parking brake.

Shown on VAS 5051 display:





- Select function "04 - Basic setting".

Shown on VAS 5051 display:





• The request to enter a display group number appears in display field - 1 -.

• An entry keypad is shown in display field - 2 -.

- Using entry keypad in display field - 2 -, enter " 6" for "Display group number 006" and confirm by pressing Q button (Pistons run together). The brake piston runs out for 20 seconds and falls out of the brake caliper.

• If the brake piston has not fallen out after 20 seconds, switch ignition off and back on again after 10 seconds. Then press the electromechanical parking brake switch. The brake piston runs out again for another 20 seconds.

- Switch ignition off.

- Remove brake piston and pressure nut from brake caliper.

- Remove old protective cap from brake piston.

- Remove old seal from brake caliper using Trim Removal Wedge (3409).





Installing

- Install new seal in brake caliper.

- Place new protective cap on brake pistons as shown.





- Install pressure nut - 1 - in brake caliper as far as stop and then loosen pressure nut a quarter turn.





- Insert protective cap in brake caliper groove. Use Trim Removal Wedge (3409) to do so.





- Carefully slide brake piston into brake caliper. Move brake piston when doing so. Brake piston must be guided over pressure nut, this is only possible in four positions.

- After brake piston has been guided onto pressure nut, press it as far as stop into brake caliper.





• Ensure pressure nut is not damaged.

- Piston resetting tool (T10145) can also be used to press brake piston back in.





- Ensure protective cap is guided into brake piston groove when piston is pressed all the way in.

- Insert brake pad retaining springs





- Measure pad strength of both brake pads without backing plates and note smaller value.

• Round measured value to a whole number. The value must be between 3 and 14. If the value is under 3, use new brake pads.

- Insert brake pads.





- Make sure that the brake pads are located correctly in anti-rattle springs - arrows -.





- Secure brake caliper housing using new self-locking bolts.





• The repair kit includes four self-locking hex bolts which must be installed in all cases.

- Install electronic parking brake connector in bracket.





- Switch on ignition.

- Close and open electrical parking brake three times. Wait each time until parking brake actuator has reached the end position.

- Switch ignition off and back on again after 10 seconds. => OBD; "Address word" 52 parking brake.

Shown on VAS 5051 display:





- Select function "04 - Basic setting".

Shown on VAS 5051 display:





• The request to enter a display group number appears in display field - 1 -.

• An entry keypad is shown in display field - 2 -.

- Using entry keypad in display field - 2 -, enter " 10" for "Display group number 10" and confirm by pressing Q button (system check). Brake function is checked. The electronic parking brake opens and closes completely three times. => OBD; "Address word" 52 parking brake.

Shown on VAS 5051 display:





- Selection function "10 - Adaptation".

Shown on VAS 5051 display:





• The request to enter a channel number appears in display field - 1 -.

• An entry keypad is shown in display field - 2 -.

- Using entry keypad in display field - 2 -, enter " 6" for "Display group number 06" and confirm by pressing Q button (pad thickness entry).

Shown on VAS 5051 display:





• "Channel 6, reading and testing" is shown in display field - 1 -.

• The pad thickness values determined are shown in area - 2 -.

• A slide bar with a code for current saved pad thickness appears in area - 3 -.

- The pad thickness can change within the determined limits (3 to 14) via the slide bars.

• If a pad thickness is entered using the slide bar that lies outside the determined thresholds, this is shown but not implemented.

• If a pad thickness that is too large or too small is entered via the slide bar, the display resets itself.

Entry can also be done using keypad.

- Press button - 4 - (to enter via keypad).





Shown on VAS 5051 display:





• The display "Enter adaptation value entry value: 0 to 65535" appears in display field - 1 -.

• An entry keypad is shown in display field - 2 -.

- Enter previously measured pad thickness via entry keypad in display field - 2 - and confirm by pressing Q button.

Shown on VAS 5051 display:





• The new pad thickness value entered appears in area - 3 - above slide bar.

- Save new pad thickness by pressing button - 5 -.

Shown on VAS 5051 display:





• Display "Save channel 6" appears in display field - 1 -.

• The pad thickness values determined are shown in area - 2 -.

• The original and new pad thickness value entered appears in area - 3 -.

- Implement and save new pad thickness by pressing button - 4 -.

• Display "Save channel 6 value 0 to 23 " appears in display field - 1 -.

- End OBD and switch ignition off.

- Install wheels.

- Check brake fluid level, and fill if necessary.
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