Brake system

Chapter overview

• Materials
  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
  4
• 3.1 Technical data for brakes
  4
• 4 Brake test
  12
• 4.1 General information
  12
• 4.2 Checking vehicles with front-wheel drive
  12
• Anti-lock brake system
  13
• 1 General information
  13
• 2 Overview of fitting locations
  15
• 2.1 Overview of fitting locations - ABS/ESP
  15
• 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
  20
• 3.3 Separating control unit from hydraulic unit
  43
• 3.4 Fitting control unit to hydraulic unit
  45
• 3.5 Connecting brake lines to hydraulic unit
  46
• 4 Sensors
  48
• 4.1 Assembly overview - speed sensor on front axle
  48
• 4.2 Assembly overview - speed sensor on rear axle
  49
• 4.3 Removing and installing ESP sensor unit G419
  50
• 4.4 Removing and installing speed sensors on front axle G45/G47
  50
• 4.5 Removing and installing speed sensors on rear axle G44/G46
  51
• 4.6 Checking ABS sensor ring
  53
• Brakes - mechanism
  55
• 1 Front brake
  55
• 1.1 Assembly overview - front brake
  55
• 1.2 Removing and installing brake pads
  57
• 1.3 Removing and installing brake caliper
  60
• 1.4 Removing and installing brake carrier
  62
• 1.5 Removing and installing brake disc
  64
• 1.6 Removing and installing brake splash plate
  67
• 2 Rear brake
  70
• 2.1 Assembly overview - rear brakes
  70
• 2.2 Removing and installing brake pads
  74
• 2.3 Removing and installing brake caliper
  83
• 2.4 Removing and installing brake carrier
  90
• 2.5 Removing and installing brake disc
  93
• 2.6 Removing and installing brake splash plate
  95
• 3 Parking brake
  99
• 3.1 Assembly overview - parking brake
  99
• 3.2 Adjusting parking brake
  99
• 3.3 Removing and installing rear brake cable
  101
• 4 Brake pedal
  107
• 4.1 Assembly overview - brake pedal
  107
• 4.2 Removing and installing mounting bracket
  109
• 4.3 Separating brake pedal from brake servo
  111
• 4.4 Connecting brake pedal to brake servo
  112
• 4.5 Removing and installing brake pedal
  112
• Brakes - hydraulics
  114
• 1 Front brake caliper
  114
• 1.1 Assembly overview – front brake caliper
  114
• 1.2 Removing and installing brake caliper piston
  115
• 2 Rear brake caliper
  118
• 2.1 Assembly overview – rear brake caliper
  118
• 2.2 Removing and installing brake caliper piston
  122
• 3 Brake servo and brake master cylinder
  126
• 3.1 Assembly overview - brake servo/brake master cylinder
  126
• 3.2 Removing and installing brake light switch
  128
• 3.3 Removing and installing brake servo
  130
• 3.4 Removing and installing brake master cylinder
  138
• 3.5 Removing and installing brake fluid reservoir
  144
• 4 Vacuum system
  148
• 4.1 Assembly overview - electric vacuum pump
  148
• 4.2 Assembly overview - vacuum pump
  149
• 4.3 Checking non-return valve
  150
• 4.4 Removing and installing vacuum sender G608
  151
• 4.5 Checking vacuum system
  151
• 5 Brake lines
  158
• 5.1 Repairing brake lines
  158
• 6 Hydraulic system
  164
• 6.1 General notes on brake fluid
  164
• 6.2 Pre-bleeding hydraulic system
  164
• 6.3 Bleeding hydraulic system following standard procedure
  167
• 6.4 Subsequent bleeding of hydraulic system
  168
• 6.5 Testing for leaks
  169