Brake systems

Chapter overview

• Technical data
  1
• 1 Brake allocation via PR No
  1
• 1.1 Front brakes
  1
• 1.2 Rear brakes
  2
• 2 Technical data for brakes
  3
• 2.1 Brake master cylinder and brake servo
  3
• 2.2 Front brakes FN 3
  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 70 (ABS/TCS)
  10
• 4.2 ABS Mark 60 (ABS/EDL/TCS/ESP) up to Week 22/2008
  12
• 4.3 ABS Mark 60 (ABS/EDL/TCS/ESP) from Week 22/2008
  14
• 4.4 ABS Mark 60 EC (ABS/EDL/TCS/ESP) from Week 22/2008, LHD
  16
• 5 Fault display via warning lamps
  19
• 6.1 ABS Mark 70 (ABS/TCS) (LHD vehicle)
  21
• 6.2 ABS Mark 70 (ABS/TCS) (RHD vehicle)
  29
• 6.3 ABS Mark 60 (ABS/EDL/TCS/ESP) to Week 22/2008, LHD
  36
• 6.4 ABS Mark 60 EC (ABS/EDL/TCS/ESP) from Week 22/2008, LHD
  44
• 6.5 ABS Mark 60 EC (ABS/EDL/TCS/ESP) (RHD vehicle)
  52
• 7 Removing and installing parts of ABS system on front and rear axle
  61
• 7.1 Removing and installing parts of ABS system on front axle
  61
• 7.2 Removing and installing parts of ABS system on rear axle
  62
• 8 Removing and installing parts of ESP system
  65
• 8.1 Removing and installing ESP sensor unit G419
  65
• 8.2 Removing and installing steering angle sender G85
  65
• Brakes - mechanism
  67
• 1 Repairing front brakes
  67
• 1.1 Repairing front brakes, FN 3 brake caliper
  67
• 1.2 Removing and installing brake pads, brake caliper FN 3
  70
• 1.3 Removing and installing brake caliper, FS III brake caliper
  72
• 2 Repairing rear brakes
  77
• 2.1 Assembly overview - rear brake CII 41
  77
• 2.2 Removing and installing brake pads, CII 41
  79
• 2.3 Removing and installing brake caliper, CII 41
  81
• 2.4 Assembly overview - Bosch rear wheel brake
  84
• 2.5 Removing and installing brake pads, Bosch
  86
• 2.6 Removing and installing brake caliper, Bosch
  88
• 3 Assembly overview - handbrake lever
  92
• 3.1 Removing and installing handbrake cable up to model year 2007
  92
• 3.2 Removing and installing handbrake cable from model year 2008
  94
• 3.3 Adjusting handbrake
  96
• 4 Assembly overview - brake pedal
  98
• 4.1 Assembly overview - brake pedal, left-hand drive
  98
• 4.2 Assembly overview - brake pedal, right-hand drive
  103
• Brakes - hydraulics
  108
• 1 Repairing front brake caliper
  108
• 1.1 Repairing brake caliper FN 3
  108
• 1.2 Removing and installing piston for brake caliper FN 3
  108
• 2 Repairing rear brake caliper
  112
• 2.1 Assembly overview - brake caliper CII 41
  112
• 2.2 Removing and installing piston for brake caliper CII 41
  113
• 2.3 Assembly overview - Bosch brake caliper
  115
• 2.4 Removing and installing brake caliper piston, Bosch
  117
• 3 Pressurised leak test
  120
• 3.1 Test prerequisites:
  120
• 4 Bleeding brake system
  121
• 4.1 Bleeding brake system with the brake filling and bleeding equipment VAS 5234
  121
• 4.2 Changing brake fluid
  123
• 5 Brake servo and brake master cylinder
  124
• 5.1 Assembly overview - brake servo/brake master cylinder to Week 22/2008, LHD
  124
• 5.2 Assembly overview - brake servo/brake master cylinder from Week 22/2008, LHD
  126
• 5.3 Assembly overview - brake servo/brake master cylinder (right-hand drive vehicle)
  128
• 5.4 Overview - vacuum pump for brake servo (diesel vehicles)
  130
• 5.5 Vacuum pump for brake servo (vehicles with 2.0 l petrol engine)
  130
• 5.6 Checking brake servo vacuum system
  131
• 5.7 Checking non-return valve
  135
• 5.8 Removing and installing vacuum sender G608
  135
• 5.9 Removing and installing brake servo pressure sensor G294
  135
• 5.10 Removing and installing brake servo vacuum sender G483 to Week 22/2008
  136
• 5.11 Vacuum pump for brakes V192
  136
• 5.12 Removing and installing brake light switch F from Week 45/2005, LHD
  137
• 5.13 Removing and installing brake light switch F , right-hand drive
  138
• 6 Removing and installing brake master cylinder
  141
• 6.1 Removing and installing brake master cylinder, left-hand drive
  141
• 6.2 Removing and installing brake master cylinder, right-hand drive
  142
• 7 Removing and installing brake servo
  147
• 7.1 Removing and installing brake servo, left-hand drive
  147
• 7.2 Removing and installing brake servo, right-hand drive vehicle
  150
• 8 Repairing brake lines
  160
• 8.1 Assembly overview - flanging tool
  162
• 8.2 Work instructions
  162