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
  7
• 4.1 General information
  7
• 4.2 Brake check on single-axle roller dynamometer
  7
• Anti-lock brake system
  8
• 1 General information
  8
• 2 Overview of fitting locations
  10
• 2.1 Overview of fitting locations – ABS/ESP
  10
• 3 Control unit and hydraulic unit
  13
• 3.1 Assembly overview – control unit and hydraulic unit
  13
• 3.2 Removing and installing ABS control unit J104 and ABS hydraulic unit N55
  17
• 3.3 Separating control unit from hydraulic unit
  28
• 3.4 Fitting control unit to hydraulic unit
  30
• 3.5 Connecting brake lines to hydraulic unit
  31
• 4 Sensors
  34
• 4.1 Assembly overview – speed sensor on front axle
  34
• 4.2 Assembly overview – speed sensors on rear axle
  35
• 4.3 Removing and installing speed sensors on front axle G45/G47
  36
• 4.4 Removing and installing speed sensors on rear axle G44/G46
  37
• 4.5 Checking ABS sensor ring
  38
• Brakes - mechanism
  40
• 1 Front brake
  40
• 1.1 Assembly overview – front brake
  40
• 1.2 Removing and installing brake pads
  42
• 1.3 Removing and installing brake caliper
  45
• 1.4 Removing and installing brake disc
  49
• 1.5 Removing and installing brake splash plate
  50
• 2 Rear brake
  52
• 2.1 Assembly overview - rear brakes
  52
• 2.2 Removing and installing brake pads
  58
• 2.3 Removing and installing brake caliper
  62
• 2.4 Removing and installing brake carrier
  64
• 2.5 Removing and installing brake disc
  65
• 2.6 Removing and installing brake shoes
  67
• 2.7 Resetting drum brakes
  75
• 2.8 Removing and installing brake splash plate
  76
• 3 Parking brake
  78
• 3.1 Assembly overview – parking brake
  78
• 3.2 Removing and installing handbrake lever
  80
• 3.3 Removing and installing handbrake warning switch F9
  82
• 3.4 Adjusting parking brake
  83
• 3.5 Removing and installing rear brake cable
  85
• 4 Brake pedal
  93
• 4.1 Assembly overview – brake pedal
  93
• 4.2 Separating brake pedal from brake servo
  96
• 4.3 Connecting brake pedal to brake servo
  97
• 4.4 Removing and installing mounting bracket
  98
• 4.5 Removing and installing brake pedal
  101
• Brakes - hydraulics
  103
• 1 Front brake caliper
  103
• 1.1 Assembly overview – front brake caliper
  103
• 1.2 Removing and installing brake caliper piston
  104
• 2 Rear brake caliper
  107
• 2.1 Assembly overview – rear brake caliper
  107
• 2.2 Removing and installing brake caliper piston
  109
• 3 Brake servo and brake master cylinder
  112
• 3.1 Assembly overview – brake servo/brake master cylinder
  112
• 3.2 Removing and installing brake light switch
  117
• 3.3 Removing and installing brake servo
  118
• 3.4 Removing and installing brake master cylinder
  127
• 3.5 Removing and installing brake fluid reservoir
  133
• 4 Vacuum system
  141
• 4.1 Assembly overview - vacuum pump
  141
• 4.2 Checking non-return valve
  142
• 4.3 Removing and installing vacuum sender G608
  143
• 4.4 Checking vacuum system
  144
• 4.5 Removing and installing electric vacuum pump
  150
• 5 Brake lines
  152
• 5.1 Repairing brake lines
  152
• 6 Hydraulic system
  158
• 6.1 General notes on brake fluid
  158
• 6.2 Bleeding hydraulic system following standard procedure
  158
• 6.3 Subsequent bleeding of hydraulic system
  159
• 6.4 Testing for leaks
  161