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
  4
• 3.1 Technical data for brakes
  4
• 4 Brake test
  8
• 4.1 General information
  8
• 4.2 Checking vehicles with front-wheel drive
  8
• 4.3 Checking vehicles with all-wheel drive
  8
• 4.4 Checking parking brake
  9
• Anti-lock brake system
  11
• 1 General information
  11
• 1.1 Repair instructions for repair work on ABS
  11
• 2 Overview of fitting locations
  14
• 2.1 Overview of fitting locations - ABS/ESP
  14
• 3 Control unit and hydraulic unit
  16
• 3.1 Assembly overview - control unit and hydraulic unit
  16
• 3.2 Removing and installing ABS control unit J104 and ABS hydraulic unit N55
  20
• 3.3 Separating control unit from hydraulic unit
  38
• 3.4 Fitting control unit to hydraulic unit
  39
• 3.5 Connecting brake lines to hydraulic unit
  40
• 4 Sensors
  42
• 4.1 Assembly overview - speed sensor on front axle
  42
• 4.2 Assembly overview - speed sensor on rear axle
  43
• 4.3 Removing and installing speed sensors on front axle G45 / G47
  44
• 4.4 Removing and installing speed sensors on rear axle G44 / G46
  45
• 4.5 Checking ABS sensor ring
  46
• 4.6 Removing and installing ESP sensor unit G419
  47
• Brakes - mechanism
  48
• 1 Front brake
  48
• 1.1 Assembly overview - front brake
  48
• 1.2 Removing and installing brake pads
  51
• 1.3 Removing and installing brake caliper
  54
• 2 Rear brake
  57
• 2.1 Assembly overview - rear brakes
  57
• 2.2 Removing and installing brake pads
  59
• 2.3 Removing and installing brake caliper
  64
• 3 Parking brake
  69
• 3.1 Overview of fitting locations - parking brake
  69
• 3.2 Removing and installing control unit for electromechanical parking brake J540
  70
• 3.3 Removing and installing parking brake motor V282 / V283
  70
• 4 Brake pedal
  73
• 4.1 Assembly overview - brake pedal
  73
• 4.2 Removing and installing mounting bracket
  76
• 4.3 Separating brake pedal from brake servo
  80
• 4.4 Connecting brake pedal to brake servo
  81
• 4.5 Removing and installing brake pedal
  81
• Brakes - hydraulics
  83
• 1 Front brake caliper
  83
• 1.1 Assembly overview – front brake caliper
  83
• 1.2 Removing and installing brake caliper piston
  84
• 2 Rear brake caliper
  87
• 2.1 Assembly overview – rear brake caliper
  87
• 2.2 Removing and installing protective cap
  87
• 3 Brake servo and brake master cylinder
  91
• 3.1 Assembly overview - brake servo/brake master cylinder
  91
• 3.2 Removing and installing brake light switch
  96
• 3.3 Removing and installing brake servo
  99
• 3.4 Removing and installing brake master cylinder
  113
• 4 Vacuum system
  123
• 4.1 Assembly overview - vacuum pump
  123
• 4.2 Checking non-return valve
  127
• 4.3 Removing and installing vacuum sender G608
  128
• 4.4 Checking vacuum system
  128
• 4.5 Removing and installing electric vacuum pump
  132
• 5 Brake lines
  135
• 5.1 Repairing brake lines
  135
• 6 Hydraulic system
  139
• 6.1 General notes on brake fluid
  139
• 6.2 Bleeding hydraulic system following standard procedure
  139
• 6.3 Subsequent bleeding of hydraulic system
  140
• 6.4 Testing for leaks
  141