Brake systems

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety measures when working on vehicles with a start/stop system
  1
• 2 Identification
  2
• 2.1 Allocation of PR number - brakes
  2
• 3 Repair instructions
  3
• 3.1 Rules for cleanliness
  3
• 3.2 General repair instructions
  3
• 3.3 Checking vacuum system
  3
• 4 Technical data
  5
• 4.1 Technical data for brakes
  5
• 5 Brake test
  8
• 5.1 General information
  8
• 5.2 Checking vehicles with rear-wheel drive
  8
• 5.3 Checking vehicles with all-wheel drive
  8
• Anti-lock brake system
  10
• 1 General information
  10
• 1.1 General notes on ABS
  10
• 1.2 Repair instructions for repair work on ABS
  11
• 2 Overview of fitting locations
  12
• 2.1 Overview of fitting locations - (ABS, EDL, TCS, ESP)
  12
• 3 Control unit and hydraulic unit
  17
• 3.1 Assembly overview - control unit and hydraulic unit
  17
• 3.2 Removing and installing ABS control unit J104 and ABS hydraulic unit N55
  21
• 3.3 Removing and installing ABS control unit J104 without ABS hydraulic unit N55
  31
• 3.4 Separating control unit from hydraulic unit
  34
• 3.5 Fitting control unit to hydraulic unit
  35
• 3.6 Connecting brake lines to hydraulic unit
  37
• 4 Sensors
  42
• 4.1 Assembly overview - front axle speed sensors G45/G47
  42
• 4.2 Assembly overview - rear axle speed sensors G44/G46
  42
• 4.3 Removing and installing front axle speed sensors G45/G47
  44
• 4.4 Removing and installing rear axle speed sensors G44/G46
  45
• Brakes - mechanism
  48
• 1 Front brake
  48
• 1.1 Assembly overview - front brake
  48
• 1.2 Removing and installing brake pads
  51
• 1.3 Removing and installing brake caliper
  54
• 2 Rear brake
  57
• 2.1 Assembly overview - rear brakes
  57
• 2.2 Removing and installing brake pads
  63
• 2.3 Removing and installing brake caliper
  66
• 2.4 Removing and installing brake carrier
  70
• 2.5 Removing and installing brake shoes
  71
• 2.6 Resetting drum brakes
  76
• 2.7 Removing and installing wheel brake cylinder
  78
• 3 Parking brake
  81
• 3.1 Assembly overview - parking brake
  81
• 3.2 Assembly overview - brake cable
  81
• 3.3 Removing and installing handbrake lever
  83
• 3.4 Removing and installing front handbrake cable
  85
• 3.5 Removing and installing rear handbrake cable
  86
• 3.6 Adjusting parking brake
  91
• 4 Brake pedal
  95
• 4.1 Assembly overview - brake pedal
  95
• 4.2 Removing and installing brake pedal
  95
• Brakes - hydraulics
  97
• 1 Front brake caliper
  97
• 1.1 Assembly overview – front brake caliper
  97
• 1.2 Removing and installing brake caliper piston
  98
• 2 Rear brake caliper
  101
• 2.1 Assembly overview – rear brake caliper
  101
• 2.2 Removing and installing brake caliper piston
  101
• 3 Hydraulic system
  106
• 3.1 General notes on brake fluid
  106
• 3.2 Pre-bleeding hydraulic system
  107
• 3.3 Bleeding hydraulic system following standard procedure
  109
• 3.4 Subsequent bleeding of hydraulic system
  109
• 3.5 Leakage test
  109
• 4 Brake servo and brake master cylinder
  111
• 4.1 Assembly overview - brake servo/brake master cylinder
  111
• 4.2 Removing and installing brake light switch F
  113
• 4.3 Removing and installing brake servo
  114
• 4.4 Removing and installing brake master cylinder
  125
• 4.5 Removing and installing brake fluid reservoir
  128
• 5 Vacuum system
  131
• 5.1 Assembly overview – vacuum pump
  131
• 5.2 Checking non-return valve
  131
• 5.3 Removing and installing non-return valve
  131
• 5.4 Checking vacuum system
  132
• 6 Brake lines
  137
• 6.1 Repairing brake lines
  137