Brake system

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety measures when working on vehicles with a start/stop system
  1
• 2 Identification
  3
• 2.1 Allocation of PR number - brakes
  3
• 3 Repair instructions
  4
• 3.1 Checking vacuum system
  4
• 4 Technical data
  5
• 4.1 Technical data for brakes
  5
• 5 Brake test
  8
• 5.1 General information
  8
• 5.2 Checking vehicles with front-wheel drive
  8
• 5.3 Checking vehicles with all-wheel drive
  8
• 6 Hazard classification of high-voltage system
  10
• 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
  17
• 3.1 Assembly overview – control unit and hydraulic unit
  17
• 3.2 Removing and installing ABS control unit J104 and ABS hydraulic unit N55
  19
• 3.3 Separating control unit from hydraulic unit
  25
• 3.4 Fitting control unit to hydraulic unit
  26
• 3.5 Connecting brake lines to hydraulic unit
  28
• 4 Sensors
  30
• 4.1 Assembly overview – speed sensor on front axle
  30
• 4.2 Assembly overview – speed sensors on rear axle
  30
• 4.3 Removing and installing brake light switch
  32
• 4.4 Removing and installing speed sensors on front axle G45/G47
  35
• 4.5 Removing and installing speed sensors on rear axle G44/G46
  36
• Brakes - mechanism
  37
• 1 Front brake
  37
• 1.1 Assembly overview – front brake
  37
• 1.2 Removing and installing brake pads
  39
• 1.3 Removing and installing brake caliper
  43
• 1.4 Removing and installing brake carrier
  45
• 1.5 Removing and installing brake disc
  47
• 1.6 Removing and installing brake splash plate
  49
• 2 Rear brake
  53
• 2.1 Assembly overview - rear brakes
  53
• 2.2 Removing and installing brake pads
  55
• 2.3 Removing and installing brake caliper
  58
• 2.4 Removing and installing brake carrier
  61
• 2.5 Removing and installing brake disc
  64
• 2.6 Removing and installing brake splash plate
  66
• 3 Parking brake
  69
• 3.1 Assembly overview – parking brake
  69
• 3.2 Adjusting parking brake
  69
• 3.3 Removing and installing rear brake cable
  71
• 4 Brake pedal
  76
• 4.1 Assembly overview – brake pedal
  76
• 4.2 Removing and installing mounting bracket
  78
• 4.3 Removing and installing brake light switch
  82
• 4.4 Separating brake pedal from brake servo
  82
• 4.5 Connecting brake pedal to brake servo
  83
• Brakes - hydraulics
  85
• 1 Front brake caliper
  85
• 1.1 Assembly overview – front brake caliper
  85
• 1.2 Removing and installing brake caliper piston
  86
• 2 Rear brake caliper
  90
• 2.1 Assembly overview – rear brake caliper
  90
• 2.2 Removing and installing brake caliper piston
  92
• 3 Brake servo and brake master cylinder
  95
• 3.1 Assembly overview – brake servo/brake master cylinder
  95
• 3.2 Removing and installing brake servo
  99
• 3.3 Removing and installing brake master cylinder
  107
• 3.4 Removing and installing brake fluid reservoir
  118
• 4 Vacuum system
  124
• 4.1 Assembly overview - electric vacuum pump
  124
• 4.2 Assembly overview - vacuum pump
  125
• 4.3 Checking non-return valve
  125
• 4.4 Removing and installing non-return valve
  126
• 4.5 Removing and installing brake servo pressure sensor
  127
• 4.6 Checking vacuum system
  128
• 5 Brake lines
  133
• 5.1 Repairing brake lines
  133
• 6 Hydraulic system
  140
• 6.1 General notes on brake fluid
  140
• 6.2 Pre-bleeding hydraulic system
  140
• 6.3 Bleeding hydraulic system following standard procedure
  141
• 6.4 Subsequent bleeding of hydraulic system
  142
• 6.5 Testing for leaks
  143