Brake systems

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Allocation of PR number - brakes
  1
• 2 Technical data
  2
• 2.1 Technical data for brakes
  2
• 3 Brake test
  4
• 3.1 General information
  4
• 3.2 Checking vehicles with front-wheel drive
  4
• 3.3 Checking vehicles with four-wheel drive
  4
• 3.4 Checking parking brake
  5
• Anti-lock brake system
  7
• 1 General information
  7
• 1.1 Repair instructions for repair work on ABS
  7
• 1.2 Vehicle diagnosis, testing and information system
  8
• 2 Overview of fitting locations
  10
• 2.1 ABS/ESP
  10
• 3 Control unit and hydraulic unit
  14
• 3.1 Assembly overview
  14
• 3.2 Removing and installing control unit and hydraulic unit
  17
• 3.3 Connecting brake lines to hydraulic unit
  25
• 4 Sensors
  28
• 4.1 Assembly overview - speed sensor on front axle
  28
• 4.2 Removing and installing speed sensor on front axle
  29
• 4.3 Assembly overview - speed sensor on rear axle
  29
• 4.4 Removing and installing speed sensor on rear axle
  31
• 4.5 Removing and installing ESP sensor unit
  32
• 4.6 Removing and installing steering angle sender
  33
• 4.7 Removing and installing brake servo vacuum sender
  33
• Brakes - mechanism
  35
• 1 Front brakes
  35
• 1.1 Assembly overview - front brakes
  35
• 1.2 Removing and installing brake pads/linings
  38
• 1.3 Removing and installing brake caliper
  43
• 2 Rear brakes
  47
• 2.1 Assembly overview - rear brakes
  47
• 2.2 Removing and installing brake pads/linings
  50
• 2.3 Removing and installing brake caliper
  53
• 3 Handbrake
  56
• 3.1 Overview of fitting locations - parking brake
  56
• 3.2 Removing and installing control unit
  57
• 3.3 Removing and installing parking brake motor
  57
• 4 Brake pedal
  60
• 4.1 Assembly overview - brake pedal
  60
• 4.2 Separating brake pedal from brake servo
  62
• 4.3 Connecting brake pedal to brake servo
  63
• 4.4 Removing and installing brake pedal
  63
• 4.5 Removing and installing mounting bracket
  66
• Brakes - hydraulics
  71
• 1 Front brake calipers
  71
• 1.1 Assembly overview - front brake caliper
  71
• 1.2 Removing and installing brake caliper piston
  72
• 2 Rear brake calipers
  78
• 2.1 Assembly overview - rear brake caliper
  78
• 2.2 Removing and installing rear brake caliper piston
  79
• 3 Brake servo and brake master cylinder
  82
• 3.1 Assembly overview - brake servo/brake master cylinder
  82
• 3.2 Removing and installing brake light switch
  86
• 3.3 Removing and installing brake master cylinder
  88
• 3.4 Removing and installing brake servo
  102
• 4 Vacuum system
  120
• 4.1 Assembly overview - vacuum pump
  120
• 4.2 Assembly overview - electric vacuum pump
  121
• 4.3 Checking non-return valve
  122
• 4.4 Removing and installing brake servo pressure sensor
  122
• 4.5 Checking vacuum system
  122
• 5 Brake lines
  127
• 5.1 Repairing brake lines
  127
• 6 Hydraulic system
  132
• 6.1 General notes on brake fluid
  132
• 6.2 Pre-bleeding hydraulic system
  132
• 6.3 Bleeding hydraulic system following standard procedure
  134
• 6.4 Subsequent bleeding of hydraulic system
  135
• 6.5 Testing for leaks
  135