Brake systems

Chapter overview

• Technical data
  1
• 2 Brake test
  9
• 2.1 General
  9
• 2.2 Test for vehicles with front-wheel drive
  9
• 2.3 Test for vehicles with four-wheel drive
  9
• Anti-lock brake system
  11
• 1 General notes for anti-lock brake system (ABS)
  11
• 2 Notes for repair work on anti-locking brake system
  12
• 3 Electrical/electronic components and fitting locations
  13
• 3.1 ABS/EDL/TCS Bosch 5.3
  13
• 3.2 ABS/EDL/TCS/ESP Bosch 5.3 up to model year 2000
  15
• 3.3 ABS/EDL/TCS/ESP Bosch 5.3 as of model year 2001
  17
• 3.4 ABS/EDL/TCS/ESP Bosch 5.7 as of model year 2002
  19
• 4 Fault display via warning lamps
  22
• 4.1 ABS/EDL/TCS Bosch 5.3
  22
• 4.2 ABS/EDL/TCS/ESP
  26
• 5 Assembly overview - hydraulic unit, brake servo/brake master cylinder
  30
• 5.1 Bosch ABS 5.3 up to model year 1999
  30
• 5.2 Bosch ABS 5.3 as of model year 2000
  36
• 5.3 ABS/EDL/TCS/ESP Bosch 5.3 up to model year 1999
  43
• 5.4 ABS/EDL/TCS/ESP Bosch 5.3 as of model year 2000
  48
• 5.5 ABS/EDL/TCS/ESP Bosch 5.7 as of model year 2002
  53
• 6 Removing and installing parts of ABS system on front and rear axle
  59
• 6.1 Removing and installing parts of ABS system on front axle
  59
• 6.2 Removing and installing parts of ABS system on rear axle (vehicles with front-wheel drive)
  60
• 6.3 Removing and installing parts of ABS system on rear axle (vehicles with four-wheel drive)
  64
• 7 Removing and installing parts of ESP system
  68
• 7.1 Removing and installing ABS control unit J104 (Bosch 5.3)
  68
• 7.2 Removing and installing yaw rate sender G202
  69
• 7.3 Removing and installing lateral acceleration sender G200
  70
• 7.5 Removing and installing steering angle sender G85
  71
• Brakes - mechanism
  73
• 1 Repairing front brakes
  73
• 1.1 Repairing front brakes, brake caliper C54
  73
• 1.2 Removing and installing brake pads, brake caliper C54
  75
• 1.3 Repairing front brakes, brake caliper FN3
  77
• 1.4 Removing and installing brake pads, brake caliper FN3
  80
• 1.5 Repairing front brakes, brake caliper HP-2
  83
• 1.6 Removing and installing brake pads, brake caliper HP-2
  86
• 1.7 Repairing front brakes, brake caliper 2FN
  88
• 1.8 Removing and installing brake pads, brake caliper 2FN
  91
• 2 Repairing rear brakes (disc brakes)
  95
• 2.1 Removing and installing brake pads
  97
• 3 Repairing handbrake
  100
• 3.1 Assembly overview - handbrake lever
  100
• 3.2 Removing and installing handbrake lever
  100
• 3.3 Removing and installing handbrake cables (front-wheel drive)
  101
• 3.4 Removing and installing handbrake cables (four-wheel drive)
  104
• 3.5 Adjusting handbrake
  106
• 4 Assembly overview - brake pedal
  108
• 4.1 Brake pedal in LHD vehicles
  108
• 4.2 Removing and installing brake pedal (LHD vehicles)
  109
• 4.3 Brake pedal in LHD vehicles
  110
• 4.4 Removing and installing brake pedal (RHD vehicles)
  111
• Brakes - hydraulics
  116
• 1 Repairing front brake calipers
  116
• 1.1 Repairing brake calipers C54
  116
• 1.2 Removing and installing piston for brake caliper C54
  117
• 1.3 Repairing brake caliper HP2
  119
• 1.4 Removing and installing piston HP2 brake caliper
  119
• 1.5 Repairing brake caliper 2FN
  121
• 1.6 Removing and installing piston for brake caliper 2FN
  122
• 2 Repairing front brake calipers, brake caliper FN3
  126
• 2.1 Removing and installing front brake caliper piston
  126
• 3 Repairing rear brake caliper
  129
• 3.1 Removing and installing piston for rear brake caliper
  130
• 3.2 Pressure leak test
  132
• 4 Bleeding brake system
  134
• 4.2 Bleeding brake system without brake filling and bleeding unit
  136
• 4.3 Changing brake fluid (every 2 years)
  136
• 5 Assembly overview - brake servo/brake master cylinder
  137
• 5.1 Vehicles up to model year 1999
  137
• 5.2 Vehicles as of model year 2000
  139
• 5.3 Vehicles as of model year 2002
  141
• 5.4 Vacuum pump for brake servo (diesel vehicles) overview
  142
• 6 Vacuum pump for brakes V192
  144
• 6.1 Assembly overview
  144
• 6.2 Removing and installing vacuum pump for brakes V192
  144
• 6.3 Testing brake vacuum pump V192
  145
• 6.4 Removing and installing brake servo pressure sensor G294
  147
• 7 Removing and installing brake master cylinder
  148
• 7.1 Vehicles up to model year 1999
  148
• 7.2 Vehicles as of model year 2000
  149
• 8 Removing and installing brake servo
  151
• 8.1 Vehicles up to model year 1999
  151
• 8.2 Vehicles as of model year 2000
  153
• 9.1 Removing
  156
• 9.2 Installing
  158