Brake system

Kapitelübersicht

• Technical data
  1
• 1 Identification
  1
• 1.1 Allocation of PR number - brakes
  1
• 2 Notes on safety
  3
• 2.1 Safety precautions when working on vehicles with Start/Stop system
  3
• 2.2 Safety precautions during a road test using test and measuring equipment
  3
• 3 Technical data
  4
• 3.1 Technical data for brakes
  4
• 4 Brake test
  7
• 4.1 General information
  7
• 4.2 Checking vehicles with front-wheel drive
  7
• Anti-lock brake system
  8
• 1 General information
  8
• 1.1 Repair instructions for repair work on ABS
  8
• 2 Overview of fitting locations
  10
• 2.1 Overview of fitting locations - ABS/ESP
  10
• 3 Control unit and hydraulic unit
  12
• 3.1 Assembly overview - control unit and hydraulic unit
  12
• 3.2 Removing and installing ABS control unit J104 and ABS hydraulic unit N55
  16
• 3.3 Separating control unit from hydraulic unit
  27
• 3.4 Fitting control unit to hydraulic unit
  27
• 3.5 Connecting brake lines to hydraulic unit
  28
• 4 Sensors
  30
• 4.1 Assembly overview - speed sensor on front axle
  30
• 4.2 Assembly overview - speed sensor on rear axle
  31
• 4.3 Removing and installing speed sensors on front axle G45 / G47
  31
• 4.4 Removing and installing speed sensors on rear axle G44 / G46
  32
• Brakes - mechanism
  33
• 1 Front brakes
  33
• 1.1 Assembly overview - front brakes
  33
• 1.2 Removing and installing brake pads or linings
  39
• 1.3 Removing and installing brake caliper
  46
• 2 Rear brakes
  54
• 2.1 Assembly overview - rear brakes
  54
• 2.2 Removing and installing brake pads or linings
  60
• 2.3 Removing and installing brake caliper
  68
• 3 Handbrake
  77
• 3.1 Assembly overview - parking brake
  77
• 3.2 Adjusting parking brake
  77
• 3.3 Removing and installing rear brake cable
  78
• 4 Brake pedal
  81
• 4.1 Assembly overview - brake pedal
  81
• 4.2 Removing and installing mounting bracket
  83
• 4.3 Separating brake pedal from brake servo
  86
• 4.4 Connecting brake pedal to brake servo
  86
• 4.5 Removing and installing brake pedal
  87
• Brakes - hydraulics
  90
• 1 Front brake caliper
  90
• 1.1 Assembly overview - front brake caliper
  90
• 1.2 Removing and installing brake caliper piston
  92
• 2 Rear brake caliper
  98
• 2.1 Assembly overview - rear brake caliper
  98
• 2.2 Removing and installing brake caliper piston
  102
• 3 Brake booster and brake master cylinder
  105
• 3.1 Assembly overview - brake servo/brake master cylinder
  105
• 3.2 Removing and installing brake light switch
  109
• 3.3 Removing and installing brake booster
  111
• 3.4 Removing and installing brake master cylinder
  120
• 4 Vacuum system
  127
• 4.1 Checking non-return valve
  127
• 4.2 Removing and installing vacuum sender G608
  127
• 4.3 Checking vacuum system
  127
• 4.4 Removing and installing vacuum pump
  132
• 5 Brake lines
  134
• 5.1 Repairing brake lines
  134
• 6 Hydraulic system
  139
• 6.1 General notes on brake fluid
  139
• 6.2 Bleeding hydraulic system following standard procedure
  139
• 6.3 Subsequent bleeding of hydraulic system
  140
• 6.4 Testing for leaks
  141