Brakes

Kapitelübersicht

• Technical data
  1
• 1 Brake allocation via PR No
  1
• 1.1 Front brakes
  1
• 1.2 Rear brakes
  2
• 2 Technical data for brakes
  3
• 2.1 Brake master cylinder and brake servo
  3
• 2.2 Front brakes
  3
• 2.3 Rear brakes
  5
• 3 Brake test
  7
• 3.1 General
  7
• 3.2 Test for vehicles with front-wheel drive
  7
• Anti-lock brake system
  8
• 1 General notes for anti-lock brake system (ABS)
  8
• 1.1 Bosch 8.2
  8
• 2 Notes for repair work on anti-lock brake system
  10
• 3 Connecting VAS 5051 and selecting functions
  11
• 4 Electrical/electronic components and locations
  13
• 4.1 Bosch 8.2 ABS
  13
• 4.2 Bosch 8.2i ABS/EDL/TCS/ESP
  14
• 5 Fault display via warning lamps
  17
• 6 Assembly overview - hydraulic unit, brake servo/brake master cylinder
  20
• 6.1 Bosch 8.2 ABS, left-hand drive
  20
• 6.2 Bosch 8.2 ABS, right-hand drive
  30
• 6.3 Bosch 8.2i ABS/EDS/ASR/ESP, left-hand drive
  40
• 6.4 Bosch 8.2i ABS/EDS/ASR/ESP, right-hand drive
  50
• 7 Removing and installing parts of ABS system on front and rear axle
  61
• 7.1 Removing and installing parts of ABS system on front axle
  61
• 7.3 Removing and installing parts of anti-lock brake system on rear axle (disc brakes)
  64
• 8 Removing and installing parts of ESP system
  67
• 8.2 Removing and installing steering angle sender G85
  67
• Brakes - mechanism
  68
• 1 Repairing front brakes
  68
• 1.1 Repairing front brakes, FS III brake caliper
  68
• 1.2 Removing and installing brake pads, brake caliper FS III
  70
• 1.3 Removing and installing brake caliper FS III
  72
• 1.4 Repairing front brakes, FN 3 brake caliper
  75
• 1.5 Removing and installing brake pads, brake caliper FN 3
  77
• 1.6 Removing and installing brake caliper FN 3
  80
• 2.1 Rear wheel brake (One shot (wedge) system) - assembly overview
  82
• 2.2 Brake drum (One shot (wedge) system) - position
  84
• 2.3 Brake shoes (One shot - wedge - system) - remove and install
  84
• 3.1 Assembly overview – rear brake, disc brake
  89
• 3.2 Assembly overview - rear wheel brake (Micrometric system)
  91
• 3.3 Removing and installing brake pads or linings
  93
• 3.4 Removing and installing brake caliper
  96
• 3.5 Remove and install brake shoes (Micrometric system)
  98
• 4 Handbrake
  110
• 4.1 Handbrake - assembly overview
  110
• 4.2 Handbrake cable (drum brake) - remove and install
  111
• 4.3 Handbrake (One shot (wedge) system) - adjust
  115
• 4.4 Handbrake (Micrometer system) - adjust
  117
• 5 Assembly overview - brake pedal
  119
• 5.1 Assembly overview - brake pedal, left-hand drive
  119
• 5.2 Assembly overview - brake pedal, right-hand drive
  122
• Brakes - hydraulics
  127
• 1 Repairing front brake calipers
  127
• 1.1 Repairing FS III brake calipers
  127
• 1.2 Removing and installing brake caliper FS III
  127
• 1.3 Repairing FN 3 brake calipers
  130
• 1.4 Removing and installing brake caliper piston FN 3
  130
• 2 Repairing rear brake calipers
  135
• 2.1 Removing and installing rear brake caliper piston
  136
• 3 Pressurised leak test
  140
• 3.1 Test prerequisites:
  140
• 4 Bleeding brake system
  141
• 4.1 Bleeding brake system with brake filling and bleeding equipment VAS 5234
  141
• 4.2 Changing brake fluid
  143
• 5 Assembly overview - brake servo/brake master cylinder
  144
• 5.1 Assembly overview - brake servo/brake master cylinder (left-hand drive vehicle)
  144
• 5.2 Assembly overview - brake servo/brake master cylinder (right-hand drive vehicle)
  146
• 5.3 Vacuum pump for brake servo (vehicles with diesel engine)
  148
• 5.4 Checking brake servo vacuum system
  149
• 5.5 Checking non-return valve
  154
• 5.6 Vacuum pump for brakes V192
  154
• 5.7 Removing and installing brake servo pressure sensor G294
  156
• 5.8 Removing and installing brake light switch F, left-hand drive
  157
• 5.9 Removing and installing brake light switch F, right-hand drive
  158
• 6 Removing and installing brake master cylinder
  160
• 6.1 Removing and installing brake master cylinder, left-hand drive
  160
• 6.2 Removing and installing brake master cylinder, right-hand drive vehicle
  161
• 7 Removing and installing brake servo
  166
• 7.1 Removing and installing brake servo, left-hand drive
  166
• 7.2 Removing and installing brake servo, right-hand drive vehicle
  169
• 8 Repairing brake lines
  177
• 8.1 Assembly overview - flanging tool
  178
• 8.2 Work instructions
  179