1996 AUDI A4 brake

45-1


General information on the
Anti-lock Brake System (ABS)

Information for repair work on ABS


WARNING!

Brake fluid is poisonous.

It must NEVER be removed by siphoning
with your mouth.
If brake fluid contacts skin or eyes, flush or
wash adequately to prevent irritation. Get
medical attention immediately if necessary.
Brake fluid must be disposed of properly in
compliance with environmental regulations.

CAUTION!
The anti-lock brake system is basically
maintenance-free.
Specialist knowledge is required for
performing any work on this system.
Failure to observe the instructions presented
in this Repair Manual may result in damage
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to the system and to loss of vehicle safety.
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45-2

CAUTION!

Brake fluid must never be brought into
contact with liquids containing mineral oils
(e.g. oil, fuel, cleaning agents). Mineral oils
damage the plugs and seals in the brake
system.
Brake fluid must not be allowed to come into
contact with paintwork because of its caustic
effect.
Brake fluid is hygroscopic (i.e. it absorbs
moisture from the surrounding air) and
should therefore always be stored in airtight
containers.
Always dispose of used brake fluid
properly.
Make sure that brake fluid does not enter the
electrical harness connectors.
During painting operations, the electronic
control module can be exposed to a max.
temperature of 95 C (203 F) for only a short
period, and to a maximum of 85 C (186 F)
for longer periods (approx. 2 hours).
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(ABS
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Before carrying out work using electric
welding equipment, refer to safety
precautions Repair Manual, "Body-
Collision Repair."

Thoroughly clean all unions and the adjacent
areas before loosening. Do not use
aggressive cleaning agents such as brake
cleaner, fuel, thinners or similar chemicals.
Place removed components on a clean
surface and cover.
Pa
ge 4 of 8 General information on the Anti-lock Brake S
ystem
(ABS
)
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pair&id=AUDI.B5.SU03.45.1

45-3

CAUTION! (continued)

Carefully cover or seal open parts if repairs
cannot be carried out immediately (use
sealing plugs from repair kit 1H0 698 311 A).
Part numbers are listed here for reference
only. Always check with your Parts
department for the latest information.
Do not use fluffy cloths.
Only remove replacement parts from
packaging immediately prior to installation.
When the system is open do not work with
compressed air and do not move the vehicle.
Before carrying out repairs to the ABS,
determine the cause of the malfunction using
On Board Diagnostic (OBD).

Repair Manual, ABS/EDL/ASR On Board
Diagnostic (OBD), Repair Group 01

Always check the control module coding when
installing a new hydraulic control unit.
Pa
ge 5 of 8 General information on the Anti-lock Brake S
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(ABS
)
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pair&id=AUDI.B5.SU03.45.1

Repair Manual, ABS/EDL/ASR On Board
Diagnostic (OBD), Repair Group 01
Always switch the ignition off and disconnect
the battery Ground (GND) strap before carrying
out installation or repair work.

CAUTION!

Before disconnecting the battery, determine
the correct coding for the anti-theft radio.
Pa
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(ABS
)
11/20/2002 htt
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pair&id=AUDI.B5.SU03.45.1

45-4

After finishing any work that requires opening
the brake hydraulic system, bleed the brake
system page 47
-23
. In addition, carry out a
high and low-pressure test of the brake system
page 45
-5 .

Use only packaged genuine Audi replacement
parts.
During the final road test, at least one ABS-
controlled braking operation must be performed
(normal pulsations must be felt at the brake
pedal).

Repair Manual, ABS/EDL/ASR On Board
Diagnostic (OBD), Repair Group 01
Pa
ge 7 of 8 General information on the Anti-lock Brake S
ystem
(ABS
)
11/20/2002 htt
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e=re
pair&id=AUDI.B5.SU03.45.1

45-5

High- and low-pressure test


Requirement

The conventional brake system (brake
master cylinder, brake hoses, brake lines
and brake calipers) are in proper order and
free of leaks.

High-pressure test

Low-pressure test - Remove bleeder screw at front brake caliper. Connect pressure gauge
VAG1310 or VAG1310A and bleed.
- Insert brake pedal depressor between brake pedal and driver's seat.
Apply pressure to brake pedal until gauge indicates pressure of 50 bar
(725 psi).
Pressure must not drop by more than 4 bar (58 psi) during the test
period of 45 seconds.
- If pressure drop is greater, replace ABS hydraulic unit.
- Turn back brake pedal depressor until pressure gauge indicates
system pressure of 6 bar (87 psi). Pressure must not drop by more than 1 bar (14 psi) during test period
of 3 minutes.
- If pressure drop is greater, replace ABS hydraulic unit.
Pa
ge 8 of 8 General information on the Anti-lock Brake S
ystem
(ABS
)
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.SU03.45.1