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
  10
• 2 Overview of fitting locations
  13
• 2.1 Overview of fitting locations - ABS/ESP
  13
• 3 Control unit and hydraulic unit
  15
• 3.1 Assembly overview - control unit and hydraulic unit
  15
• 3.2 Removing and installing ABS control unit J104 / ABS hydraulic unit N55
  21
• 3.3 Separating control unit from hydraulic unit
  32
• 3.4 Fitting control unit to hydraulic unit
  33
• 3.5 Connecting brake lines to hydraulic unit
  35
• 4 Sensors
  37
• 4.1 Assembly overview - speed sensor on front axle
  37
• 4.2 Assembly overview - speed sensor on rear axle
  38
• 4.3 Removing and installing ESP sensor unit G419
  41
• 4.4 Removing and installing speed sensors on front axle G45 / G47
  41
• 4.5 Removing and installing speed sensors on rear axle G44 / G46
  42
• 4.6 Removing and installing steering angle sender G85
  43
• Brakes - mechanism
  44
• 1 Front brakes
  44
• 1.1 Assembly overview - front brakes
  44
• 1.2 Removing and installing brake pads or linings
  48
• 1.3 Removing and installing brake caliper
  53
• 2 Rear brakes
  58
• 2.1 Assembly overview - rear brakes
  58
• 2.2 Removing and installing brake pads or linings
  63
• 2.3 Removing and installing brake caliper
  66
• 2.4 Removing and installing brake shoes
  67
• 2.5 Retracting drum brakes
  70
• 3 Handbrake
  71
• 3.1 Assembly overview - parking brake
  71
• 3.2 Adjusting parking brake
  72
• 3.3 Removing and installing rear brake cable
  74
• 4 Brake pedal
  80
• 4.1 Assembly overview - brake pedal
  80
• 4.2 Removing and installing mounting bracket
  83
• 4.3 Separating brake pedal from brake servo
  84
• 4.4 Connecting brake pedal to brake servo
  85
• 4.5 Removing and installing brake pedal
  86
• Brakes - hydraulics
  87
• 1 Front brake caliper
  87
• 1.1 Assembly overview - front brake caliper
  87
• 1.2 Removing and installing brake caliper piston
  88
• 2 Rear brake caliper
  94
• 2.1 Assembly overview - rear brake caliper
  94
• 2.2 Removing and installing brake caliper piston
  95
• 3 Brake servo and brake master cylinder
  97
• 3.1 Assembly overview - brake servo/brake master cylinder
  97
• 3.2 Removing and installing brake light switch
  100
• 3.3 Removing and installing brake servo
  102
• 3.4 Removing and installing brake master cylinder
  140
• 4 Vacuum system
  148
• 4.1 Assembly overview - vacuum pump
  148
• 4.2 Checking non-return valve
  149
• 4.3 Removing and installing brake servo pressure sensor
  150
• 4.4 Checking vacuum system
  150
• 4.5 Removing and installing electrical vacuum pump for brakes
  155
• 5 Brake lines
  157
• 5.1 Repairing brake lines
  157
• 6 Hydraulic system
  162
• 6.1 General notes on brake fluid
  162
• 6.2 Pre-bleeding hydraulic system
  162
• 6.3 Bleeding hydraulic system following standard procedure
  163
• 6.4 Subsequent bleeding of hydraulic system
  164
• 6.5 Testing for leaks
  165