Brake systems

Kapitelübersicht

• Technical data
  1
• 1 Identification
  1
• 1.1 Allocation of PR number - brakes
  1
• 2 Technical data
  2
• 2.1 Technical data for brakes
  2
• 3 Brake test
  5
• 3.1 General information
  5
• 3.2 Checking vehicles with front-wheel drive
  5
• 3.3 Checking vehicles with all-wheel drive
  5
• Anti-lock brake system
  6
• 1 General information
  6
• 1.1 General information for repair work on ABS
  6
• 1.2 Repair instructions for repair work on ABS
  7
• 2 Overview of fitting locations
  9
• 2.1 Components and fitting locations MK25 (ABS/EDL/TCS/ESP)
  9
• 2.2 Components and locations MK25 (ABS/EDL/TCS)
  11
• 2.3 Components and fitting locations MK25E (ABS/EDL/TCS/ESP)
  12
• 2.4 Components and locations MK25E (ABS/ABS)
  14
• 2.6 Faults displayed by warning lamps for ABS / EDL / TCS
  17
• 2.7 Faults displayed by warning lamps, ABS/EDL/TCS/ESP
  19
• 2.8 Faults displayed by warning lamps ABS/EDL/TCS/ESP, model year 2010 ►
  21
• 3 Control unit and hydraulic unit
  25
• 3.1 Assembly overview - ABS control unit J104 / ABS hydraulic unit N55 , MK25
  25
• 3.3 Removing and installing ABS control unit J104 / ABS hydraulic unit N55 , MK25
  28
• 3.5 Connecting brake lines to hydraulic unit, MK25
  35
• 3.6 Connecting brake lines to hydraulic unit, MK25E/MK25E1 and MK25A, model year 2010 ►
  35
• 3.7 Separating ABS control unit J104 from ABS hydraulic unit N55
  36
• 4 Sensors
  37
• 4.1 Assembly overview - speed sensor on front axle
  37
• 4.2 Assembly overview - speed sensor on rear axle
  38
• 4.3 Removing and installing speed sensor on front axle
  38
• 4.4 Removing and installing speed sensor on rear axle
  39
• 4.5 Removing and installing steering angle sender G85
  39
• Brakes - mechanism
  41
• 1 Front brakes
  41
• 1.1 Assembly overview - front brake, floating caliper disc brake FN3
  41
• 1.2 Assembly overview - front brake, floating caliper disc brake 2FNR 44
  44
• 1.3 Removing and installing brake pads, floating caliper disc brake FN3
  45
• 1.4 Removing and installing brake pads, floating caliper disc brake 2FNR 44
  48
• 1.5 Removing and installing brake caliper
  53
• 1.6 Removing and installing brake disc
  62
• 1.7 Removing brake carrier
  63
• 2 Rear brakes
  64
• 2.1 Assembly overview - rear brakes
  64
• 2.2 Removing and installing brake pads/linings
  68
• 2.3 Removing and installing brake caliper
  74
• 3 Parking brake
  81
• 3.1 Assembly overview - parking brake
  81
• 3.2 Adjusting parking brake
  81
• 3.3 Removing and installing front brake cable
  83
• 3.4 Removing and installing rear brake cable
  86
• 4 Brake pedal
  93
• 4.1 Assembly overview - brake pedal
  93
• 4.2 Removing and installing brake light switch F
  94
• 4.3 Separating brake pedal from brake servo
  96
• 4.4 Removing and installing brake pedal
  97
• Brakes - hydraulics
  99
• 1 Front brake caliper
  99
• 1.1 Assembly overview - front brake caliper, floating caliper disc brake FN3
  99
• 1.2 Assembly overview - front brake caliper, floating caliper disc brake 2FNR44
  101
• 1.3 Removing and installing brake caliper piston, floating caliper disc brake FN3
  102
• 2 Rear brake caliper
  108
• 2.1 Assembly overview - rear brake caliper
  108
• 2.2 Assembly overview - rear brake caliper, brake caliper FN 44
  109
• 2.3 Removing and installing brake caliper piston
  110
• 2.4 Removing and installing brake caliper piston, brake caliper FN 44
  112
• 3 Hydraulic system
  116
• 3.1 Pre-bleeding hydraulic system
  116
• 3.2 Bleeding hydraulic system following standard procedure
  117
• 3.3 Subsequent bleeding of hydraulic system
  117
• 3.4 Testing for leaks
  118
• 4 Brake servo and brake master cylinder
  119
• 4.1 Assembly overview - brake servo/brake master cylinder MK25
  119
• 4.2 Assembly overview - brake servo/brake master cylinder MK25E/MK25E1
  121
• 4.5 Removing and installing brake pressure sender -1- G201 , MK25
  125
• 4.6 Removing and installing brake servo MK25
  126
• 4.7 Removing and installing brake servo MK25E/MK25E1
  128
• 4.8 Removing and installing brake fluid reservoir
  131
• 4.9 Removing and installing brake master cylinder
  133
• 5 Vacuum system
  136
• 5.1 Assembly overview - vacuum pump for brakes V192
  136
• 5.2 Removing and installing vacuum pump for brakes V192
  136
• 5.3 Checking vacuum pump for brakes V192
  137
• 5.4 Checking non-return valve
  137