Brake system

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.2 Safety precautions when working on a high-voltage system
  1
• 1.3 Safety precautions when working in the vicinity of high-voltage components
  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
  7
• 4.1 General information
  7
• 4.2 Checking vehicles with front-wheel drive
  7
• 4.3 Checking vehicles with all-wheel drive
  7
• 4.4 Checking parking brake
  8
• Anti-lock brake system
  10
• 1 General information
  10
• 1.1 Repair instructions for repair work on ABS
  10
• 2 Overview of fitting locations
  13
• 2.1 Overview of fitting locations – ABS/ESP
  13
• 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
  21
• 3.3 Connecting brake lines to hydraulic unit
  36
• 3.4 Separating control unit from hydraulic unit
  39
• 3.5 Fitting control unit to hydraulic unit
  40
• 4 Sensors
  42
• 4.1 Assembly overview – speed sensor on front axle
  42
• 4.2 Assembly overview – speed sensors on rear axle
  43
• 4.3 Removing and installing ESP sensor unit G419
  44
• 4.4 Removing and installing speed sensors on front axle G45/G47
  44
• 4.5 Removing and installing speed sensors on rear axle G44/G46
  45
• 4.6 Checking ABS sensor ring
  47
• 4.7 Removing and installing steering angle sender G85
  48
• Brakes - mechanism
  49
• 1 Front brake
  49
• 1.1 Assembly overview – front brake
  49
• 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
  65
• 3 Parking brake
  70
• 3.1 Overview of fitting locations – parking brake
  70
• 3.2 Removing and installing control unit for electromechanical parking brake J540
  71
• 3.3 Removing and installing parking brake motor V282/V283
  71
• 4 Brake pedal
  74
• 4.1 Assembly overview – brake pedal
  74
• 4.2 Removing and installing mounting bracket
  77
• 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
  82
• Brakes - hydraulics
  86
• 1 Front brake caliper
  86
• 1.1 Assembly overview – front brake caliper
  86
• 1.2 Removing and installing brake caliper piston
  88
• 2 Rear brake caliper
  91
• 2.1 Assembly overview – rear brake caliper
  91
• 2.2 Removing and installing protective cap
  92
• 3 Brake servo and brake master cylinder
  96
• 3.1 Assembly overview – brake servo/brake master cylinder
  96
• 3.2 Removing and installing brake servo
  100
• 3.3 Removing and installing brake master cylinder
  106
• 3.4 Removing and installing brake fluid level warning contact F34
  120
• 4 Brake lines
  122
• 4.1 Repairing brake lines
  122
• 5 Hydraulic system
  126
• 5.1 General notes on brake fluid
  126
• 5.2 Bleeding hydraulic system following standard procedure
  126
• 5.3 Subsequent bleeding of hydraulic system
  127
• 5.4 Testing for leaks
  128