Brake system

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety measures when working on vehicles with a start/stop system
  1
• 2 Identification
  2
• 2.1 Allocation of PR number - brakes
  2
• 3 Technical data
  3
• 3.1 Technical data for brakes
  3
• 4 Brake test
  6
• 4.1 General information
  6
• 4.2 Checking vehicles with front-wheel drive
  6
• Anti-lock brake system
  7
• 1 General information
  7
• 1.1 Repair instructions for repair work on ABS
  7
• 2 Overview of fitting locations
  10
• 2.1 Fitting location overview - ABS
  10
• 2.2 Overview of fitting locations - ABS/ESP
  12
• 3 Control unit and hydraulic unit
  18
• 3.1 Assembly overview - control unit and hydraulic unit
  18
• 3.2 Removing and installing ABS control unit J104 and ABS hydraulic unit N55
  29
• 3.3 Separating control unit from hydraulic unit
  114
• 3.4 Fitting control unit to hydraulic unit
  116
• 3.5 Connecting brake lines to hydraulic unit
  119
• 4 Sensors
  124
• 4.1 Assembly overview - sensors and actuators
  124
• 4.2 Assembly overview - speed sensor on front axle
  126
• 4.3 Assembly overview - speed sensor on rear axle
  127
• 4.4 Removing and installing speed sensors on front axle G45 / G47
  127
• 4.5 Removing and installing speed sensors on rear axle G44 / G46
  128
• Brakes - mechanism
  130
• 1 Front brakes
  130
• 1.1 Assembly overview - front brakes
  130
• 1.2 Removing and installing brake pads/linings
  137
• 1.3 Removing and installing brake caliper
  144
• 1.4 Removing and installing brake carrier
  150
• 1.5 Removing and installing brake disc
  152
• 1.6 Removing and installing brake splash plate
  157
• 2 Rear brakes
  161
• 2.1 Assembly overview - rear brakes
  161
• 2.2 Removing and installing brake pads/linings
  163
• 2.3 Removing and installing brake caliper
  166
• 2.4 Removing and installing brake carrier
  170
• 2.5 Removing and installing brake disc
  172
• 2.6 Removing and installing brake splash plate
  174
• 3 Parking brake
  177
• 3.1 Assembly overview - parking brake
  177
• 3.2 Removing and installing handbrake lever
  177
• 3.3 Adjusting parking brake
  181
• 3.4 Removing and installing rear brake cable
  183
• 4 Brake pedal
  187
• 4.1 Assembly overview - brake pedal
  187
• 4.2 Removing and installing mounting bracket
  189
• 4.3 Separating brake pedal from brake servo
  195
• 4.4 Connecting brake pedal to brake servo
  196
• 4.5 Removing and installing brake pedal
  196
• Brakes - hydraulics
  199
• 1 Front brake caliper
  199
• 1.1 Assembly overview - front brake caliper
  199
• 1.2 Removing and installing brake caliper piston
  201
• 2 Rear brake caliper
  207
• 2.1 Assembly overview - rear brake caliper
  207
• 2.2 Removing and installing brake caliper piston
  208
• 2.3 Pre-bleeding brake caliper
  211
• 3 Brake servo and brake master cylinder
  212
• 3.1 Assembly overview - brake servo/brake master cylinder
  212
• 3.2 Removing and installing brake light switch
  217
• 3.3 Removing and installing brake servo
  221
• 3.4 Removing and installing brake master cylinder
  264
• 3.5 Removing and installing brake fluid reservoir
  291
• 4 Vacuum system
  298
• 4.1 Assembly overview - electric vacuum pump
  298
• 4.2 Assembly overview - vacuum pump
  300
• 4.3 Checking non-return valve
  302
• 4.4 Removing and installing vacuum sender G608
  302
• 4.5 Checking vacuum system
  302
• 4.6 Removing and installing electric vacuum pump
  307
• 5 Brake lines
  309
• 5.1 Repairing brake lines
  309
• 6 Hydraulic system
  314
• 6.1 General notes on brake fluid
  314
• 6.2 Pre-bleeding hydraulic system
  316
• 6.3 Bleeding hydraulic system following standard procedure
  318
• 6.4 Subsequent bleeding of hydraulic system
  321
• 6.5 Testing for leaks
  322