Brake system

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety precautions when working on high-voltage system
  1
• 1.2 Safety precautions when working in the vicinity of high-voltage components
  2
• 1.3 Safety measures when working on vehicles with a start/stop system
  2
• 1.4 Safety precautions when using test and measuring instruments during a road test
  2
• 2 Identification
  3
• 2.1 Allocation of PR number - brakes
  3
• 3 Technical data
  5
• 3.1 Technical data for brakes
  5
• 4 Brake test
  8
• 4.1 General information
  8
• 4.2 Checking vehicles with front-wheel drive
  8
• Anti-lock brake system
  9
• 1 General information
  9
• 1.1 Repair instructions for repair work on ABS
  9
• 1.2 Vehicle diagnosis, testing and information system
  11
• 2 Overview of fitting locations
  13
• 2.1 Fitting location overview - ABS
  13
• 2.2 Overview of fitting locations - ABS/ESP
  16
• 3 Control unit and hydraulic unit
  21
• 3.1 Assembly overview - control unit and hydraulic unit
  21
• 3.2 Removing and installing ABS control unit J104 and ABS hydraulic unit N55
  29
• 3.3 Separating control unit from hydraulic unit
  126
• 3.4 Fitting control unit to hydraulic unit
  129
• 3.5 Connecting brake lines to hydraulic unit
  134
• 4 Sensors
  137
• 4.1 Assembly overview - speed sensor on front axle
  137
• 4.2 Assembly overview - speed sensor on rear axle
  138
• 4.3 Removing and installing yaw rate sender and lateral acceleration sender
  139
• 4.4 Assembly overview - sensors and actuators
  140
• 4.5 Removing and installing speed sensors on front axle G45 / G47
  140
• 4.6 Removing and installing speed sensors on rear axle G44 / G46
  141
• Brakes - mechanism
  143
• 1 Front brakes
  143
• 1.1 Assembly overview - front brakes
  143
• 1.2 Removing and installing brake pads/linings
  150
• 1.3 Removing and installing brake caliper
  156
• 1.4 Removing and installing brake carrier
  163
• 1.5 Replace brake disc
  165
• 1.6 Removing and installing brake splash plate
  170
• 2 Rear brakes
  174
• 2.1 Assembly overview - rear brakes
  174
• 2.2 Removing and installing brake pads/linings
  184
• 2.3 Removing and installing brake caliper
  191
• 2.4 Removing and installing brake carrier
  198
• 2.5 Removing and installing brake disc
  200
• 2.6 Removing and installing brake splash plate
  202
• 3 Parking brake
  207
• 3.1 Assembly overview - parking brake
  207
• 3.2 Removing and installing handbrake lever
  208
• 3.3 Adjusting parking brake
  211
• 3.4 Removing and installing rear brake cable
  212
• 4 Brake pedal
  219
• 4.1 Assembly overview - brake pedal
  219
• 4.2 Removing and installing mounting bracket
  222
• 4.3 Separating brake pedal from brake servo
  233
• 4.4 Connecting brake pedal to brake servo
  234
• 4.5 Removing and installing brake pedal
  235
• Brakes - hydraulics
  237
• 1 Front brake caliper
  237
• 1.1 Assembly overview - front brake caliper
  237
• 1.2 Removing and installing brake caliper piston
  239
• 2 Rear brake caliper
  245
• 2.1 Assembly overview - rear brake caliper
  245
• 2.2 Removing and installing brake caliper piston
  248
• 3 Brake servo and brake master cylinder
  253
• 3.1 Assembly overview - brake servo/brake master cylinder
  253
• 3.2 Removing and installing brake light switch
  257
• 3.3 Removing and installing brake servo
  261
• 3.4 Removing and installing brake master cylinder
  299
• 3.5 Removing and installing brake fluid reservoir
  325
• 4 Vacuum system
  334
• 4.1 Assembly overview - electric vacuum pump
  334
• 4.2 Assembly overview - vacuum pump
  340
• 4.3 Checking non-return valve
  342
• 4.4 Removing and installing brake servo pressure sensor
  342
• 4.5 Removing and installing vacuum sender G608
  342
• 4.6 Checking vacuum system
  343
• 4.7 Removing and installing electric vacuum pump
  348
• 5 Brake lines
  353
• 5.1 Repairing brake lines
  353
• 6 Hydraulic system
  358
• 6.1 General notes on brake fluid
  358
• 6.2 Pre-bleeding hydraulic system
  361
• 6.3 Bleeding hydraulic system following standard procedure
  363
• 6.4 Subsequent bleeding of hydraulic system
  366
• 6.5 Testing for leaks
  367