Brake system (hybrid)

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
  4
• 3.1 Technical data for brakes
  4
• 4 Brake test
  5
• 4.1 General information
  5
• 4.2 Checking vehicles with front-wheel drive
  5
• 4.3 Checking parking brake
  5
• Anti-lock brake system
  7
• 1 General information
  7
• 1.1 Repair instructions for repair work on ABS
  7
• 2 Overview of fitting locations
  10
• 2.1 Overview of fitting locations - ABS/ESP
  10
• 3 Control unit and hydraulic unit
  12
• 3.1 Assembly overview - control unit and hydraulic unit
  12
• 3.2 Removing and installing ABS control unit J104 and ABS hydraulic unit N55
  19
• 3.3 Connecting brake lines to hydraulic unit
  29
• 3.4 Separating control unit from hydraulic unit
  31
• 3.5 Fitting control unit to hydraulic unit
  33
• 4 Sensors
  35
• 4.1 Assembly overview - speed sensor on front axle
  35
• 4.2 Assembly overview - speed sensor on rear axle
  36
• 4.3 Removing and installing ESP sensor unit G419
  36
• 4.4 Removing and installing speed sensors on front axle G45 / G47
  36
• 4.5 Checking ABS sensor ring
  37
• 4.6 Removing and installing speed sensors on rear axle G44 / G46
  38
• 4.7 Removing and installing steering angle sender G85
  39
• Brakes - mechanism
  40
• 1 Front brakes
  40
• 1.1 Assembly overview - front brakes
  40
• 1.2 Removing and installing brake pads/linings
  41
• 1.3 Removing and installing brake caliper
  44
• 2 Rear brakes
  47
• 2.1 Assembly overview - rear brakes
  47
• 2.2 Removing and installing brake pads/linings
  49
• 2.3 Removing and installing brake caliper
  53
• 3 Parking brake
  58
• 3.1 Overview of fitting locations - parking brake
  58
• 3.2 Removing and installing control unit for electromechanical parking brake J540
  59
• 3.3 Removing and installing parking brake motor V282 / V283
  59
• 4 Brake pedal
  62
• 4.1 Assembly overview - brake pedal
  62
• 4.2 Separating brake pedal from brake servo
  65
• 4.3 Connecting brake pedal to brake servo
  66
• 4.4 Removing and installing brake pedal
  67
• 4.5 Removing and installing mounting bracket
  68
• Brakes - hydraulics
  73
• 1 Front brake caliper
  73
• 1.1 Assembly overview - front brake caliper
  73
• 1.2 Removing and installing brake caliper piston
  74
• 2 Rear brake caliper
  77
• 2.1 Assembly overview - rear brake caliper
  77
• 2.2 Removing and installing protective cap
  77
• 3 Brake servo and brake master cylinder
  81
• 3.1 Assembly overview - brake servo/brake master cylinder
  81
• 3.2 Assembly overview – brake system pressure accumulator VX70
  88
• 3.3 Removing and installing brake master cylinder
  91
• 3.4 Removing and installing brake system pressure accumulator VX70
  101
• 3.5 Removing and installing brake servo
  111
• 4 Brake lines
  125
• 4.1 Repairing brake lines
  125
• 5 Hydraulic system
  130
• 5.1 General notes on brake fluid
  130
• 5.2 Bleeding hydraulic system following standard procedure
  130
• 5.3 Subsequent bleeding of hydraulic system
  132
• 5.4 Pre-bleeding brake system pressure accumulator VX70
  133
• 5.5 Testing for leaks
  133