Brake systems

Kapitelübersicht

• Technical data
  1
• 1 Technical data for brakes
  1
• 1.1 Brake allocation via PR No
  1
• 1.2 Technical data for brakes
  2
• Anti-lock brake system
  5
• 1 Connecting VAS 5051 and selecting functions
  5
• 2 Anti-lock brake system (ABS) Mark 20 IE, vehicles up to 09.2000
  7
• 2.1 General notes on ABS Mark 20 IE
  7
• 2.2 Distinguishing features of ABS Mark 20 IE
  8
• 2.3 Notes on repairing the ABS Mark 20 IE
  8
• 20 IE, vehicles up to 09.2000
  16
• 7.1 Removing and installing control unit and hydraulic unit
  21
• 8 Anti-lock brake system (ABS) Mark 60, vehicles from 10.2000
  25
• 8.1 General notes on ABS Mark 60
  25
• 8.2 Notes for repairs on ABS, ABS/EDL
  26
• 10.2000 up to and including model year 2005
  27
• 13.1 Removing and installing control unit and hydraulic unit
  39
• 14 Removing and installing parts of ABS system on front and rear axles
  43
• 14.1 Parts of ABS system on front axle
  43
• 14.2 Parts of ABS system on rear axle
  47
• 15 Removing and installing parts of ESP system
  51
• 15.2 Removing and installing ESP sensor unit G419 , vehicles from 12.2001
  54
• 15.3 Removing and installing steering angle sender G85
  55
• Brakes - mechanism
  57
• 1 Repairing front brakes, FS III brake caliper housing
  57
• 1.1 Assembly overview - FS III brake caliper housing
  57
• 1.2 Removing and installing brake pads/linings
  59
• 1.3 Removing and installing brake caliper housing
  61
• 2 Repairing front brakes, FN3 brake caliper housing
  65
• 2.1 Assembly overview - FN3 brake caliper housing
  65
• 2.2 Removing and installing brake pads/linings
  67
• 2.3 Removing and installing brake caliper housing
  70
• 3 Repairing rear brakes (disc brakes)
  74
• 3.1 Assembly overview
  74
• 3.2 Removing and installing brake pads/linings
  76
• 3.3 Removing and installing brake caliper housing
  78
• 3.4 Adjusting handbrake
  81
• 4 Removing and installing handbrake cable (disc brakes)
  82
• 4.1 Removing handbrake cable
  82
• 4.2 Installing handbrake cable
  83
• 5 Assembly overview - handbrake lever
  84
• 6 Brake pedal
  85
• 6.1 Assembly overview - brake pedal
  85
• 6.2 Separating brake pedal from, and clipping to, brake servo
  86
• 6.3 Removing and installing brake pedal
  87
• 6.6 Adjusting brake light switch , vehicles up to 02.2000
  90
• 6.7 Adjusting brake light switch , vehicles from 03.2000
  91
• Brakes - hydraulics
  92
• 1 Repairing front brake calipers, FS III brake caliper housing
  92
• 1.1 Removing and installing front brake caliper housing piston
  92
• 2 Repairing front brake calipers, FN3 brake caliper housing
  95
• 2.1 Removing and installing front brake caliper housing piston
  95
• 3 Repairing rear brake caliper
  98
• 3.1 Removing and installing rear brake caliper piston
  99
• 3.2 Pressurised leak test
  101
• 4 Brake pressure regulator
  102
• 4.1 Assembly overview - brake pressure regulator
  102
• 4.2 Checking and adjusting brake pressure regulator
  102
• 5.2 Bleeding brake system without brake filling and bleeding equipment
  107
• 6 Bleeding brake system, vehicles with ABS Mark 60 from 10.2000
  108
• 6.2 Bleeding brake system without brake filling and bleeding equipment
  110
• 7 Assembly overview - brake servo/brake master cylinder
  111
• 7.1 Removing and installing vacuum pump for brake servo (diesel vehicles)
  112
• 9 Assembly overview - vacuum pump
  117
• 9.1 Brake servo vacuum pump (5-cyl. petrol engine)
  117
• 9.2 Brake servo vacuum pump (4-cyl. petrol engine)
  117
• 10.1 Functional check of brake assist system in brake servo, from 12.2001
  119
• 10.2 Removing and installing vacuum pump for brakes V192
  119
• 10.3 Checking vacuum pump for brakes V192
  120
• 10.4 Electrical check of vacuum pump for brakes V192 , vehicles up to 05.2002
  121
• 10.5 Electrical check of vacuum pump for brakes V192 , vehicles from 06.2002
  123
• 10.6 Removing and installing brake servo pressure sensor G294
  125
• 11 Brake master cylinder, left-hand drive vehicle
  126
• 11.1 Removing and installing brake master cylinder
  126
• 12 Brake master cylinder, right-hand drive vehicle
  128
• 12.1 Removing and installing brake master cylinder
  128
• 13 Brake servo, left-hand drive vehicle
  130
• 13.1 Removing and installing brake servo
  130
• 14 Brake servo, right-hand drive vehicle
  133
• 14.1 Removing and installing brake servo
  133
• 15 Repairing brake lines
  135
• 15.1 Assembly overview - flanging tool
  137
• 15.2 Work instructions
  137