Brake systems

Kapitelübersicht

• Technical data
  1
• 1 Technical data
  1
• 1.1 Braking
  1
• 2 Brake test
  3
• 2.1 General
  3
• 2.2 Test
  3
• Anti-lock brake system
  4
• 1 Anti-lock brake system (ABS) Mark 20 IE and Mark 30 IE
  4
• 1.1 General information on this ABS
  4
• 2 Notes for repair work on anti-lock brake system
  5
• 3 Connecting VAS 5051 and selecting functions
  6
• 4 Electrical and electronic components and locations (ABS, ABS/EDL)
  8
• 5 Fault display via warning lamps
  10
• 6 Assembly overview - hydraulic unit, brake servo/brake master cylinder
  11
• 6.1 Connecting brake lines from brake master cylinder to hydraulic unit
  13
• 6.2 Removing and installing control unit and hydraulic unit
  14
• 7 Removing and installing parts of ABS system on front and rear axle
  18
• 7.1 Removing and installing parts of anti-lock brake system on front axle, brake caliper VW II
  18
• 7.2 Removing and installing parts of anti-lock brake system on front axle, Lucas brake caliper
  21
• Brakes - mechanism
  32
• 1 Repairing front brakes
  32
• 1.1 Repairing front brakes, brake caliper VW II
  32
• 1.2 Removing and installing brake pads, brake caliper VW II
  33
• 1.3 Removing and installing brake caliper VW II
  35
• 1.4 Repairing front brakes, Lucas brake calipers
  37
• 1.5 Removing and installing brake pads, Lucas brake calipers
  39
• 1.6 Removing and installing Lucas brake calipers
  41
• 2 Repairing rear brakes, drum brakes
  43
• 2.1 Removing and installing rear brakes
  43
• 2.2 Resetting brake
  45
• 2.3 Repairing rear brake
  45
• 2.4 Removing and installing brake shoes
  46
• 3 Repairing rear brake, disc brake
  48
• 3.1 Repairing rear brakes C 34
  48
• 3.2 Removing and installing brake pads/linings
  49
• 3.3 Removing and installing brake caliper
  52
• 4 Assembly overview - handbrake lever
  54
• 4.1 Removing and installing handbrake cable (drum brakes)
  55
• 4.2 Adjusting handbrake (drum brakes)
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• 4.3 Removing and installing handbrake cable (disc brakes)
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• 4.4 Adjusting handbrake (disc brakes)
  59
• 5 Assembly overview - brake pedal
  60
• 5.1 Separating brake pedal from brake servo
  60
• 5.2 Removing and installing brake pedal
  62
• 5.3 Removing and installing brake light switch F and brake pedal switch F47
  63
• Brakes - hydraulics
  65
• 1 Repairing front brake caliper, brake caliper VW II
  65
• 1.1 Removing and installing front brake caliper piston
  65
• 2 Repairing Lucas front brake calipers
  68
• 2.1 Removing and installing front brake caliper piston
  69
• 3 Repairing rear brake caliper
  71
• 3.1 Removing and installing rear brake caliper piston
  72
• 3.2 Pressurised leak test
  74
• 4 Assembly overview - brake pressure regulator
  75
• 4.1 Checking and adjusting brake pressure regulator
  75
• 4.2 Specifications for load dependent brake pressure regulator
  76
• 5 Bleeding brake system
  78
• 5.2 Bleeding brake system without brake filling and bleeding equipment
  80
• 5.3 Changing brake fluid
  80
• 6 Assembly overview - brake servo/brake master cylinder
  81
• 6.1 Removing and installing exhauster pump for brake servo (diesel vehicles)
  82
• 6.2 Checking non-return valve :
  83
• 7 Removing and installing brake master cylinder
  84
• 7.1 Removing
  84
• 7.2 Installing
  84
• 8 Removing and installing brake servo
  86
• 8.1 Removing
  86
• 8.2 Installing
  88
• 9 Repairing brake lines
  89
• 9.1 Assembly overview - flanging tool
  91
• 9.2 Work instructions
  91