Brake system

Chapter overview

• Technical data
  1
• 1 Notes on safety
  1
• 1.1 Safety precautions during a road test using test and measuring equipment
  1
• 1.2 Safety precautions when working on vehicles with start/stop system
  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 Fitting location overview
  13
• 2.1 Fitting location overview - ABS
  13
• 2.2 Fitting location overview - ABS/ESP
  15
• 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
  32
• 3.3 Separating control unit from hydraulic unit
  132
• 3.4 Fitting control unit to hydraulic unit
  135
• 3.5 Connecting brake lines to hydraulic unit
  139
• 4 Sensors
  144
• 4.1 Assembly overview - sensors and actuators
  144
• 4.2 Assembly overview - speed sensor on front axle
  146
• 4.3 Assembly overview - speed sensor on rear axle
  147
• 4.4 Removing and installing speed sensors on front axle G45 / G47
  150
• 4.5 Removing and installing speed sensors on rear axle G44 / G46
  151
• Brakes - mechanism
  154
• 1 Front brakes
  154
• 1.1 Assembly overview - front brakes
  154
• 1.2 Removing and installing brake pads or linings
  161
• 1.3 Removing and installing brake caliper
  167
• 1.4 Removing and installing brake carrier
  174
• 1.5 Removing and installing brake disc
  176
• 1.6 Removing and installing brake splash plate
  180
• 2 Rear brakes
  185
• 2.1 Assembly overview - rear brakes
  185
• 2.2 Removing and installing brake pads or linings
  199
• 2.3 Removing and installing brake caliper
  205
• 2.4 Removing and installing brake carrier
  214
• 2.5 Removing and installing brake disc
  218
• 2.6 Removing and installing brake shoes
  222
• 2.7 Retracting drum brakes
  224
• 2.8 Removing and installing brake splash plate
  225
• 3 Handbrake
  229
• 3.1 Assembly overview - parking brake
  229
• 3.2 Removing and installing handbrake lever
  230
• 3.3 Adjusting parking brake
  233
• 3.4 Removing and installing rear brake cable
  238
• 4 Brake pedal
  250
• 4.1 Assembly overview - brake pedal
  250
• 4.2 Separating brake pedal from brake servo
  252
• 4.3 Connecting brake pedal to brake servo
  254
• 4.4 Removing and installing mounting bracket
  254
• 4.5 Removing and installing brake pedal
  259
• Brakes - hydraulics
  262
• 1 Front brake caliper
  262
• 1.1 Assembly overview - front brake caliper
  262
• 1.2 Removing and installing brake caliper piston
  263
• 2 Rear brake caliper
  269
• 2.1 Assembly overview - rear brake caliper
  269
• 2.2 Removing and installing brake caliper piston
  271
• 3 Brake servo and brake master cylinder
  276
• 3.1 Assembly overview - brake servo/brake master cylinder
  276
• 3.2 Removing and installing brake servo
  281
• 3.3 Removing and installing brake master cylinder
  315
• 3.4 Removing and installing brake fluid reservoir
  339
• 3.5 Removing and installing brake light switch
  345
• 4 Vacuum system
  350
• 4.1 Assembly overview - electric vacuum pump
  350
• 4.2 Assembly overview - vacuum pump
  351
• 4.3 Checking vacuum system
  352
• 4.4 Checking non-return valve
  356
• 4.5 Removing and installing vacuum sender G608
  357
• 5 Brake lines
  358
• 5.1 Repairing brake lines
  358
• 6 Hydraulic system
  363
• 6.1 General notes on brake fluid
  363
• 6.2 Pre-bleeding hydraulic system
  365
• 6.3 Bleeding hydraulic system following standard procedure
  367
• 6.4 Subsequent bleeding of hydraulic system
  371
• 6.5 Testing for leaks
  372