Brake system

Chapter overview

• Technical data
  1
• 1 Safety information
  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
  5
• 4.1 General information
  5
• 4.2 Checking vehicles with front-wheel drive
  5
• 4.3 Checking parking brake
  5
• 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 Overview of fitting locations - ABS/ESP
  10
• 3 Control unit and hydraulic unit
  12
• 3.1 Assembly overview - control unit and hydraulic unit
  12
• 3.2 Removing and installing ABS control unit J104 and ABS hydraulic unit N55
  16
• 3.3 Separating control unit from hydraulic unit
  30
• 3.4 Fitting control unit to hydraulic unit
  32
• 3.5 Connecting brake lines to hydraulic unit
  33
• 4 Sensors
  36
• 4.1 Assembly overview - speed sensor on front axle
  36
• 4.2 Assembly overview - speed sensor on rear axle
  37
• 4.3 Removing and installing speed sensors on front axle G45 / G47
  38
• 4.4 Removing and installing speed sensors on rear axle G44 / G46
  39
• 4.5 Checking ABS sensor ring
  40
• 4.6 Removing and installing ESP sensor unit G419
  41
• Brakes - mechanism
  42
• 1 Front brakes
  42
• 1.1 Assembly overview - front brakes
  42
• 1.2 Removing and installing brake pads/linings
  44
• 1.3 Removing and installing brake caliper
  46
• 2 Rear brakes
  49
• 2.1 Assembly overview - rear brakes
  49
• 2.2 Removing and installing brake pads/linings
  51
• 2.3 Removing and installing brake caliper
  55
• 3 Parking brake
  60
• 3.1 Overview of fitting locations - parking brake
  60
• 3.2 Removing and installing control unit for electromechanical parking brake J540
  61
• 3.3 Removing and installing parking brake motor V282 / V283
  61
• 4 Brake pedal
  64
• 4.1 Assembly overview - brake pedal
  64
• 4.2 Removing and installing mounting bracket
  67
• 4.3 Separating brake pedal from brake servo
  71
• 4.4 Connecting brake pedal to brake servo
  72
• 4.5 Removing and installing brake pedal
  72
• Brakes - hydraulics
  74
• 1 Front brake caliper
  74
• 1.1 Assembly overview - front brake caliper
  74
• 1.2 Removing and installing brake caliper piston
  75
• 2 Rear brake caliper
  78
• 2.1 Assembly overview - rear brake caliper
  78
• 2.2 Removing and installing protective cap
  78
• 3 Brake servo and brake master cylinder
  82
• 3.1 Assembly overview - brake servo/brake master cylinder
  82
• 3.2 Removing and installing brake light switch
  87
• 3.3 Removing and installing brake servo
  90
• 3.4 Removing and installing brake master cylinder
  103
• 4 Vacuum system
  113
• 4.1 Assembly overview - vacuum pump
  113
• 4.2 Checking non-return valve
  119
• 4.3 Removing and installing vacuum sender G608
  119
• 4.4 Checking vacuum system
  120
• 4.5 Removing and installing electric vacuum pump
  124
• 5 Brake lines
  126
• 5.1 Repairing brake lines
  126
• 6 Hydraulic system
  130
• 6.1 General notes on brake fluid
  130
• 6.2 Bleeding hydraulic system following standard procedure
  130
• 6.3 Subsequent bleeding of hydraulic system
  131
• 6.4 Testing for leaks
  132