Brake systems

Chapter overview

• Technical data
  1
• 1 Brake allocation via PR No
  1
• 1.1 Front brakes
  1
• 1.2 Rear brakes
  1
• 2 Technical data for brakes
  3
• 2.1 Brake master cylinder and brake booster
  3
• 2.2 Front brakes
  3
• 2.3 Rear brakes (disc brakes)
  4
• 3 Brake test
  5
• 3.1 General
  5
• 3.2 Test for vehicles with front-wheel drive
  5
• Anti-lock brake system
  6
• 1 General notes on anti-lock brake system
  6
• 2 Notes for repair work on anti-lock brake system
  7
• 3 Connecting VAS 5051 and selecting functions
  8
• 4 Electrical/electronic components and locations
  10
• 4.1 ABS Mark 60 EC (ABS/EDL/TCS/ESP)
  10
• 5 Fault display via warning lamps
  13
• 6 ABS Mark 60 EC (ABS/EDL/TCS/ESP) (left-hand drive vehicle)
  15
• 6.1 Assembly overview
  15
• 7 ABS Mark 60 EC (ABS/EDL/TCS/ESP) (RHD vehicle)
  22
• 7.1 Assembly overview
  22
• 7.2 Connecting brake lines from tandem brake master cylinder to hydraulic unit
  23
• 7.3 Removing control unit and hydraulic unit
  24
• 7.4 Unscrewing control unit from hydraulic unit
  27
• 7.5 Installing new control unit to hydraulic unit
  27
• 7.6 Installing control unit and hydraulic unit
  28
• 8 Removing and installing parts of ABS system on front and rear axle
  30
• 8.1 Removing and installing parts of ABS system on front axle
  30
• 9 Removing and installing parts of ESP system
  33
• 9.1 Removing and installing steering angle sender G85
  33
• Brakes - mechanism
  34
• 1 Repairing front brakes
  34
• 1.1 Assembly overview - front brakes FN3
  34
• 1.2 Removing and installing brake pads/linings
  37
• 1.3 Removing and installing brake caliper
  39
• 1.4 Assembly overview - front brakes FNR-G
  41
• 1.5 Removing and installing brake pads/linings
  43
• 1.6 Removing and installing brake caliper
  46
• 2 Repairing rear brakes
  53
• 2.1 Assembly overview - rear brakes C 38
  53
• 2.2 Removing and installing brake pads/linings
  54
• 2.3 Removing and installing brake caliper
  56
• 2.4 Assembly overview - rear brakes CII 41
  58
• 2.5 Removing and installing brake pads/linings
  60
• 2.6 Removing and installing brake caliper
  62
• 3 Handbrake
  66
• 3.1 Assembly overview - handbrake lever
  66
• 3.2 Removing and installing handbrake cable
  66
• 3.3 Adjusting handbrake
  68
• 4 Brake pedal (left-hand drive vehicle)
  70
• 4.1 Assembly overview
  70
• 4.2 Separating brake pedal from brake booster
  70
• 5 Brake pedal (right-hand drive vehicle)
  72
• 5.1 Assembly overview
  72
• 5.2 Separating brake pedal from, and clipping to, brake booster
  72
• 5.3 Removing and installing brake pedal
  74
• 5.4 Removing and installing mounting bracket
  77
• Brakes - hydraulics
  80
• 1 Repairing front brake calipers
  80
• 1.1 Assembly overview - brake caliper FN 3
  80
• 1.2 Removing and installing piston for brake caliper FN 3
  80
• 1.3 Assembly overview - brake caliper FNR-G
  83
• 1.4 Removing and installing piston for FNR-G brake caliper
  84
• 2 Repairing rear brake calipers
  88
• 2.1 Assembly overview - brake caliper C 38
  88
• 2.2 Assembly overview - brake caliper CII 41
  89
• 2.3 Removing and installing piston for brake caliper C 38 and CII 41
  90
• 2.4 Pre-bleeding brake caliper
  92
• 3 Pressurised leak test
  93
• 3.1 Test prerequisites:
  93
• 4 Bleeding brake system
  94
• 4.1 Bleeding brake system with the brake filling and bleeding equipment VAS 5234
  94
• 4.2 Changing brake fluid
  96
• 5 Brake booster and brake master cylinder
  97
• 5.2 Assembly overview: brake booster/brake master cylinder (right-hand drive vehicle)
  98
• 5.3 Vacuum pump for brake booster (vehicles with diesel engine)
  100
• 5.4 Vacuum pump for brake booster (vehicles with petrol engine)
  100
• 5.5 Checking brake booster vacuum system
  101
• 5.6 Checking non-return valve
  105
• 5.7 Removing and installing vacuum sender G608
  105
• 5.8 Removing and installing brake light switch F
  105
• 6 Removing and installing brake master cylinder
  109
• 6.1 Removing and installing brake master cylinder, LHD
  109
• 6.2 Removing and installing brake master cylinder, RHD
  110
• 7 Removing and installing brake booster
  116
• 7.1 Removing and installing brake booster, LHD
  116
• 7.2 Removing and installing brake booster, right-hand drive vehicle
  118
• 8 Repairing brake lines
  125
• 8.1 Assembly overview - flanging tool
  127
• 8.2 Work instructions
  127