Brake system

Chapter overview

• Technical data
  1
• 1 Brake allocation via PR No
  1
• 1.1 Front brakes
  1
• 1.2 Rear brakes
  1
• 2 Technical data for brakes
  3
• 2.1 Brake master cylinder and brake servo
  3
• 2.2 Front brakes
  3
• 2.3 Rear brakes (disc brakes)
  4
• 3 Brake test
  6
• 3.1 General
  6
• 3.2 Test for vehicles with front-wheel drive
  6
• Anti-lock brake system
  7
• 1 General notes on anti-lock brake system
  7
• 2 Notes for repair work on anti-lock brake system
  8
• 3 Connecting VAS 5051 and selecting functions
  9
• 4 Electrical/electronic components and locations
  11
• 4.1 ABS Mark 60 EC (ABS/EDL/TCS/ESP)
  11
• 5 Assembly overview - hydraulic unit
  13
• 5.1 ABS Mark 60 EC (ABS/EDL/TCS/ESP)
  13
• 6 Removing and installing parts of ABS system on front and rear axle
  20
• 6.1 Removing and installing parts of ABS system on front axle
  20
• 6.2 Removing and installing parts of ABS system on rear axle
  21
• 7 Removing and installing parts of ESP system
  23
• 7.1 Removing and installing steering angle sender G85
  23
• Brakes - mechanism
  24
• 1 Repairing front brakes
  24
• 1.1 Assembly overview - front brakes FN3
  24
• 1.2 Removing and installing brake pads/linings
  27
• 1.3 Removing and installing brake caliper
  29
• 1.4 Assembly overview - front brakes FNR-G
  32
• 1.5 Removing and installing brake pads or linings
  34
• 1.6 Removing and installing brake caliper
  37
• 2 Repairing rear brakes
  44
• 2.1 Assembly overview - rear brakes C 38
  44
• 2.2 Removing and installing brake pads/linings
  45
• 2.3 Removing and installing brake caliper
  47
• 2.4 Assembly overview - rear brake CII 41
  50
• 2.5 Removing and installing brake pads or linings
  51
• 2.6 Removing and installing brake caliper
  54
• 2.7 Assembly overview - Bosch rear wheel brake
  57
• 2.8 Removing and installing brake pads, Bosch
  58
• 2.9 Removing and installing brake calipers, Bosch
  60
• 3 Handbrake
  64
• 3.1 Assembly overview - handbrake lever
  64
• 3.2 Removing and installing handbrake cable
  64
• 3.3 Adjusting handbrake
  66
• 4 Assembly overview - brake pedal
  68
• 4.1 Separating brake pedal from brake servo
  68
• Brakes - hydraulics
  70
• 1 Repairing front brake calipers
  70
• 1.1 Assembly overview - brake caliper FN 3
  70
• 1.2 Removing and installing piston for brake caliper FN 3
  70
• 1.3 Assembly overview - brake caliper FNR-G
  73
• 1.4 Removing and installing brake piston FNR-G
  74
• 2 Repairing rear brake calipers
  78
• 2.1 Assembly overview - brake caliper C 38
  78
• 2.2 Assembly overview - brake caliper CII 41
  79
• 2.3 Removing and installing piston for brake caliper C 38 and CII 41
  80
• 2.4 Assembly overview - Bosch brake caliper
  82
• 2.5 Removing and installing Bosch brake caliper piston
  84
• 2.6 Pre-bleeding brake caliper
  86
• 3 Pressurised leak test
  87
• 3.1 Test prerequisites:
  87
• 4 Bleeding brake system
  88
• 4.1 Bleeding brake system with the brake filling and bleeding equipment VAS 5234
  88
• 4.2 Changing brake fluid
  89
• 5 Brake servo and brake master cylinder
  90
• 5.1 Assembly overview: brake servo/brake master cylinder (left-hand drive vehicle)
  90
• 5.2 Vacuum pump for brake servo (vehicles with diesel engine)
  91
• 5.3 Vacuum pump for brake servo (vehicles with 2.0 l petrol engine)
  92
• 5.4 Checking brake servo vacuum system
  92
• 5.5 Checking non-return valve
  96
• 5.6 Removing and installing vacuum sender G608
  96
• 5.7 Removing and installing brake light switch F
  96
• 6 Removing and installing brake master cylinder
  98
• 6.1 Removing
  98
• 6.2 Installing
  100
• 7 Removing and installing brake servo
  101
• 7.1 Removing
  101
• 7.2 Installing
  104
• 8 Repairing brake lines
  105
• 8.1 Assembly overview - flanging tool
  107
• 8.2 Work instructions
  107