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
• 1.2 Safety precautions when using test and measuring equipment during a road test
  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 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
  12
• 2.1 Overview of fitting locations – ABS/ESP
  12
• 3 Control unit and hydraulic unit
  15
• 3.1 Assembly overview - control unit and hydraulic unit
  15
• 3.2 Removing and installing ABS control unit J104 and ABS hydraulic unit N55
  19
• 3.3 Separating control unit from hydraulic unit
  32
• 3.4 Fitting control unit to hydraulic unit
  34
• 3.5 Connecting brake lines to hydraulic unit
  35
• 4 Sensors
  37
• 4.1 Assembly overview - speed sensor on front axle
  37
• 4.2 Assembly overview – speed sensors on rear axle
  37
• 4.3 Removing and installing ESP sensor unit G419
  38
• 4.4 Removing and installing speed sensors on front axle G45/G47
  38
• 4.5 Removing and installing speed sensors on rear axle G44/G46
  39
• 4.6 Checking ABS sensor ring
  40
• Brakes - mechanism
  42
• 1 Front brake
  42
• 1.1 Assembly overview - front brake
  42
• 1.2 Removing and installing brake pads
  44
• 1.3 Removing and installing brake caliper
  47
• 1.4 Removing and installing brake carrier
  49
• 1.5 Removing and installing brake disc
  49
• 1.6 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
  54
• 2.3 Removing and installing brake caliper
  58
• 2.4 Removing and installing brake carrier
  62
• 2.5 Removing and installing brake disc
  63
• 2.6 Removing and installing brake splash plate
  64
• 3 Parking brake
  66
• 3.1 Overview of fitting locations - parking brake
  66
• 3.2 Removing and installing control unit for electromechanical parking brake J540
  68
• 3.3 Removing and installing parking brake motor V282/V283
  68
• 4 Brake pedal
  70
• 4.1 Assembly overview - brake pedal
  70
• 4.2 Removing and installing mounting bracket
  72
• 4.3 Separating brake pedal from brake servo
  75
• 4.4 Connecting brake pedal to brake servo
  76
• 4.5 Removing and installing brake pedal
  77
• Brakes - hydraulics
  80
• 1 Front brake caliper
  80
• 1.1 Assembly overview – front brake caliper
  80
• 1.2 Removing and installing brake caliper piston
  81
• 2 Rear brake caliper
  84
• 2.1 Assembly overview – rear brake caliper
  84
• 3 Brake servo and brake master cylinder
  85
• 3.1 Assembly overview - brake servo/brake master cylinder
  85
• 3.2 Removing and installing brake servo NX6
  89
• 3.3 Removing and installing brake master cylinder
  94
• 3.4 Removing and installing brake fluid level warning contact F34
  102
• 4 Brake lines
  103
• 4.1 Repairing brake lines
  103
• 5 Hydraulic system
  109
• 5.1 General notes on brake fluid
  109
• 5.2 Bleeding hydraulic system following standard procedure
  109
• 5.3 Subsequent bleeding of hydraulic system
  110
• 5.4 Testing for leaks
  111