Brake systems

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Brakes
  1
• Anti-lock brake system
  2
• 1 Anti-lock brake system (ABS/EDL) Bosch 5.0
  2
• 1.1 General information on this anti-lock brake system
  2
• 1.2 Notes on repair work on the anti-lock brake system (ABS/EDL) Bosch 5.0
  2
• 2 Electrical/electronic components and fitting locations ABS/EDL Bosch 5.0
  4
• 2.1 Fig. 1 Diagnostic connection
  5
• 3.1 Connecting brake lines to the hydraulic unit
  7
• 3.2 Removing and installing control unit and hydraulic unit
  7
• 4 Anti-lock brake system (ABS/EDL) Bosch 5.3
  10
• 4.1 General information on this anti-lock brake system
  10
• 4.2 Notes on repair work on the anti-lock brake system (ABS/EDL) Bosch 5.3
  10
• 5 Electrical/electronic components and fitting locations ABS/EDL Bosch 5.3
  12
• 5.1 Fig. 1 Diagnostic connection
  13
• 6.1 Connecting brake lines to the hydraulic unit
  15
• 6.2 Removing and installing control unit and hydraulic unit
  15
• 7 Faults displayed by warning lamps K47, K118 and K135
  18
• 8 Faults displayed by warning lamps K47, K118 and K135
  20
• 9 Removing and installing parts of ABS system on front and rear axle
  22
• 9.1 Removing and installing speed sensor with speed sensor cable on front axle
  22
• 9.2 Removing and installing speed sensor with speed sensor cable on rear axle
  24
• Brakes - mechanism
  26
• 1 Repairing front brakes
  26
• 1.1 Repairing floating caliper brake, LT 28/35
  26
• 1.2 Removing and installing brake pads
  28
• 1.3 Repairing floating caliper brake, LT 46, Perrot, Bosch (Wabco)
  30
• 1.4 Removing and installing brake pads
  32
• 2 Repairing rear brakes
  35
• 2.1 Repairing floating caliper brake, LT 28/35, ATE
  35
• 2.2 Removing and installing brake pads
  36
• 2.3 Repairing floating caliper brake, LT 35, Bosch
  39
• 2.4 Removing and installing brake pads
  40
• 2.5 Removing and installing brake shoes for the handbrake, LT 28/35
  42
• 2.6 Repairing floating caliper brake, LT 46, Perrot, Bosch (Wabco)
  45
• 2.7 Removing and installing brake pads
  47
• 2.8 Removing and installing brake shoes for the handbrake, LT 46
  49
• 3 Assembly overview - handbrake lever
  53
• 3.1 Removing and installing handbrake lever
  53
• 3.2 Removing and installing front handbrake cable
  55
• 3.3 Adjusting handbrake
  57
• 3.6 Assembly overview - pedal cluster, brake pedal
  61
• 3.7 Removing and installing brake pedal
  63
• 3.8 Adjusting the brake light switch -F-
  63
• Brakes - hydraulics
  64
• 1 Assembly overview - brake master cylinder/brake servo
  64
• 1.1 Removing and installing brake master cylinder
  64
• 1.2 Removing and installing brake servo
  65
• 2 Repairing vacuum pump
  66
• 2.1 Assembly overview for vehicles with 4-cyl. diesel engine (vacuum pump with V-belt drive)
  66
• 2.2 Removing and installing vacuum pump
  67
• 2.3 Assembly overview for vehicles with 4-cyl. diesel engine (vacuum pump with gear drive)
  67
• 2.4 Removing and installing vacuum pump
  68
• 2.5 Assembly overview for vehicles with 5-cyl. diesel engine
  69
• 2.6 Removing and installing vacuum pump
  69
• 2.7 Checking non-return valve
  70
• 3 Repairing front brake calipers
  71
• 3.1 Repairing brake calipers, LT 28/35
  71
• 3.2 Removing and installing front brake caliper piston
  71
• 3.3 Removing
  72
• 3.4 Installing
  72
• 3.5 Repairing brake caliper, LT 46, Perrot, Bosch (Wabco)
  73
• 3.6 Removing and installing front brake caliper piston
  74
• 4 Repairing rear brake caliper
  77
• 4.1 Repairing brake caliper, LT 28/35, ATE
  77
• 4.2 Removing and installing piston for rear brake caliper
  77
• 4.3 Removing
  78
• 4.4 Installing
  78
• 4.5 Repairing brake caliper, LT 35, Bosch
  79
• 4.6 Removing and installing piston for rear brake caliper
  82
• 4.7 Repairing brake caliper, LT 46, Perrot, Bosch (Wabco)
  83
• 4.8 Removing and installing piston for rear brake caliper
  84
• 5 Checking and adjusting brake pressure regulator
  87
• 5.1 Checking brake pressure regulator
  87
• 5.2 Adjusting the brake pressure regulator
  88
• 6 Bleeding the brake system on vehicles with and without ABS/EDL
  91
• 6.2 Bleeding brake system without brake filling and bleeding unit
  92
• 7 Performing self-diagnosis
  93
• 8 Definitions
  94
• 8.1 ABS/EDL
  94
• 8.2 ABD
  94
• 8.3 Speed sensor
  94
• 8.4 Rep. Gr
  94