Brake system

Chapter overview

• Technical data
  1
• 1 Brake allocation via PR No
  1
• 1.1 Front brakes
  1
• 1.2 Rear brakes
  2
• 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
  5
• 3.1 General
  5
• 3.2 Test for vehicles with front-wheel drive
  5
• 3.3 Test for vehicles with four-wheel drive
  5
• 3.4 Testing the electromechanical parking brake
  6
• Anti-lock brake system
  8
• 1 General notes on anti-lock brake system
  8
• 2 Notes for repair work on anti-lock brake system
  9
• 3 Connecting VAS 5051 and selecting functions
  10
• 4 Electrical/electronic components and locations
  12
• 4.1 ABS TRW (ABS/EDL/TCS/ESP)
  12
• 5 Assembly overview - hydraulic unit
  14
• 5.1 ABS TRW (ABS/EDL/TCS/ESP), left-hand drive vehicle
  14
• 5.2 ABS TRW (ABS/EDL/TCS/ESP), right-hand drive vehicle
  20
• 6 Removing and installing parts of ABS system on front and rear axle
  28
• 6.1 Removing and installing parts of ABS system on front axle
  28
• 7 Removing and installing parts of ESP system
  31
• 7.1 Removing and installing ESP sensor unit G419
  31
• 7.2 Removing and installing steering angle sender G85
  32
• Brakes - mechanism
  33
• 1 Repairing front brakes
  33
• 1.1 Assembly overview - front brakes FN 3
  33
• 1.2 Removing and installing brake pads/linings
  34
• 1.3 Removing and installing brake caliper
  37
• 1.4 Assembly overview- front brakes C60
  39
• 1.5 Removing and installing brake pads/linings
  40
• 1.6 Removing and installing brake caliper
  43
• 2 Repairing rear brakes
  45
• 2.1 Assembly overview - rear brake CII 41
  45
• 2.2 Removing and installing brake pads/linings
  46
• 2.3 Removing and installing brake caliper
  49
• 3 Overview of electromechanical parking brake components
  52
• 3.1 Removing and installing control unit for electromechanical parking brake J540
  52
• 3.2 Removing and installing parking brake motor
  53
• 4 Assembly overview - brake pedal
  56
• 4.1 Assembly overview - brake pedal, left-hand drive
  56
• 4.2 Assembly overview - brake pedal, right-hand drive
  58
• Brakes - hydraulics
  66
• 1 Repairing front brake calipers
  66
• 1.1 Assembly overview - brake caliper FN 3
  66
• 1.2 Removing and installing piston for brake caliper FN 3
  66
• 1.3 Assembly overview - brake caliper C 60
  69
• 1.4 Removing and installing piston for brake caliper C 60
  70
• 2 Repairing rear brake calipers
  73
• 2.1 Assembly overview - brake caliper CII 41
  73
• 2.2 Removing and installing brake caliper piston
  74
• 2.3 Pre-bleeding brake caliper
  76
• 3 Pressurised leak test
  77
• 3.1 Test prerequisites:
  77
• 4 Bleeding brake system
  78
• 4.1 Bleeding brake system with the brake filling and bleeding equipment VAS 5234
  78
• 4.2 Changing brake fluid
  80
• 5 Assembly overview - brake servo/brake master cylinder
  81
• 5.1 Assembly overview - brake servo/brake master cylinder (left-hand drive vehicle)
  81
• 5.2 Assembly overview - brake servo/brake master cylinder (right-hand drive vehicle)
  83
• 5.3 Vacuum pump for brake servo (vehicles with diesel engine)
  84
• 5.4 Vacuum pump for brake servo (vehicles with petrol engine)
  85
• 5.5 Checking brake servo vacuum system
  85
• 5.6 Checking non-return valve :
  89
• 5.7 Removing and installing vacuum sender G608
  89
• 5.8 Removing and installing brake light switch F , left-hand drive
  89
• 5.9 Removing and installing brake light switch F , right-hand drive
  90
• 6 Removing and installing brake master cylinder
  92
• 6.1 Removing and installing brake master cylinder, left-hand drive
  92
• 6.2 Removing and installing brake master cylinder, right-hand drive vehicle
  93
• 7 Removing and installing brake servo
  106
• 7.1 Removing and installing brake servo, left-hand drive
  106
• 7.2 Removing and installing brake servo, right-hand drive vehicle
  108
• 8 Brake lines
  127
• 8.1 Separating point on underbody
  127
• 8.2 Repairing brake lines
  127