Brake systems

Chapter overview

• Technical data
  1
• 1 Brake allocation via PR No
  1
• 1.1 Front brakes
  1
• 1.2 Rear brakes (disc brakes)
  2
• 1.3 Rear brakes (drum brakes)
  3
• 2 Technical data
  4
• 2.1 Brake master cylinder and brake servo
  4
• 2.2 Front brakes
  4
• 2.3 Rear brakes
  6
• 3 Brake test
  9
• 3.1 General
  9
• 3.2 Test for vehicles with front-wheel drive
  9
• 3.3 Test for vehicles with four-wheel drive via a Haldex clutch
  9
• Anti-lock brake system
  11
• 1 General notes for anti-lock brake system (ABS)
  11
• 1.1 ABS Mark 20 IE
  11
• 1.2 ABS Mark 60
  12
• 2 Notes for repairs on anti-lock brake system
  14
• 3 Connecting VAS 5051 and selecting functions
  15
• 4 Electrical/electronic components and fitting locations
  17
• 4.1 ABS, ABS/EDL and ABS/EDL/TCS Mark 20 IE
  17
• 4.2 ABS/EDL/TCS/ESP Mark 20 IE
  19
• 4.3 ABS Mark 60
  21
• 5 Faults displayed via warning lamps
  23
• 5.1 ABS Mark 20 IE
  23
• 5.2 ABS Mark 60
  25
• 6 Assembly overview - hydraulic unit, brake servo/brake master cylinder
  28
• 6.1 ABS Mark 20 IE
  28
• 6.2 ABS Mark 60
  34
• 7 Removing and installing parts of ABS system on front and rear axle
  42
• 7.1 Removing and installing parts of ABS system on front axle
  42
• 7.2 Removing and installing parts of ABS system on rear axle - Front-wheel drive
  47
• 7.3 Removing and installing parts of ABS system on rear axle - four-wheel drive
  50
• 8 Removing and installing parts of ESP system
  54
• 8.2 Removing and installing longitudinal acceleration sender -G251-
  56
• 8.3 Removing and installing ESP sensor unit G419
  57
• 8.4 Removing and installing steering angle sender G85
  58
• Brakes - mechanism
  61
• 1 Repairing front brakes
  61
• 1.1 Repairing front brakes, FS III brake caliper
  61
• 1.2 Removing and installing brake pads
  63
• 1.3 Repairing front brakes, FN 3 brake caliper
  66
• 1.4 Removing and installing brake pads
  68
• 1.5 Repairing front brakes, 2FN brake caliper
  71
• 1.6 Removing and installing brake pads
  74
• 2 Repairing rear disc brakes - front-wheel drive
  79
• 2.1 Removing and installing brake pads
  82
• 2.2 Adjusting handbrake
  84
• 3 Repairing rear disc brakes - four-wheel drive
  85
• 3.1 Removing and installing brake pads
  87
• 3.2 Adjusting handbrake
  90
• 4 Repairing rear drum brakes
  91
• 4.1 Removing and installing rear brakes
  91
• 4.2 Releasing brake shoe adjustment
  93
• 4.3 Repairing rear brakes
  93
• 4.4 Removing and installing brake shoes
  94
• 4.5 Adjusting handbrake
  96
• 5 Assembly overview - handbrake lever
  97
• 5.1 Removing and installing handbrake cable for disc brakes - front-wheel drive
  97
• 5.2 Removing and installing handbrake cables for disc brakes - four-wheel drive
  99
• 5.3 Removing and installing handbrake cable for drum brakes
  101
• 6 Assembly overview - brake pedal
  104
• 6.1 Separating brake pedal from brake servo
  104
• 6.2 Removing and installing brake pedal
  106
• 6.3 Removing, installing brake light switch F and brake pedal switch F47
  107
• Brakes - hydraulics
  110
• 1 Repairing front brake caliper
  110
• 1.1 Repairing FS III brake caliper
  110
• 1.2 Removing and installing front brake caliper piston
  110
• 1.3 Repairing FN 3 brake caliper
  112
• 1.4 Removing and installing front brake caliper piston
  113
• 1.5 Repairing brake caliper 2FN
  115
• 1.6 Removing and installing front brake caliper piston
  116
• 2 Repairing rear brake caliper
  120
• 2.1 Removing and installing piston for rear brake caliper
  121
• 3 Assembly overview - brake pressure regulator
  123
• 4 Checking and adjusting brake pressure regulator
  124
• 4.1 Checking function
  124
• 4.2 Checking and adjusting pressure
  124
• 5 Pressure leak test
  126
• 6 Bleeding brake system
  127
• 6.2 Bleeding brake system without brake filling and bleeding unit
  129
• 7 Assembly overview - brake servo/ brake master cylinder
  131
• 7.1 Removing and installing vacuum pump for brake servo (diesel vehicles)
  132
• 8.1 Removing and installing brake pressure sender 1 G201 and brake pressure sender 2 G214
  135
• 9.1 Functional check of brake assist system in brake servo
  139
• 9.2 Removing and installing brake vacuum pump V192
  139
• 9.3 Checking brake vacuum pump V192
  140
• 10 Removing and installing brake master cylinder
  141
• 11 Removing and installing brake servo
  143
• 12 Repairing brake lines
  145
• 12.1 Assembly overview - flanging tool
  147
• 12.2 Work procedures
  147