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 booster
  3
• 2.2 Front brakes
  3
• 2.3 Rear brakes (disc brakes)
  3
• 3 Brake test
  4
• 3.1 General
  4
• 3.2 Test for vehicles with front-wheel drive
  4
• 3.3 Test for vehicles with four-wheel drive via an all-wheel drive coupling
  4
• 3.4 Testing the electromechanical parking brake
  5
• Anti-lock brake system
  7
• 1 General notes on anti-lock brake system
  7
• 2 Notes for repair work on anti-lock brake system
  8
• 3 Connecting VAS 5051 and selecting functions
  9
• 4 Electrical/electronic components and locations
  11
• 4.1 ABS TRW (ABS/EDL/TCS/ESP)
  11
• 5 Assembly overview - hydraulic unit
  13
• 5.1 ABS TRW (ABS/EDL/TCS/ESP), left-hand drive vehicle
  13
• 5.2 ABS TRW (ABS/EDL/TCS/ESP), right-hand drive vehicle
  19
• 6 Removing and installing parts of ABS system on front and rear axle
  27
• 6.1 Removing and installing parts of ABS system on front axle
  27
• 7 Removing and installing parts of ESP system
  31
• 7.1 Removing and installing ESP sensor unit G419
  31
• 7.2 Removing and installing steering angle sender G85
  32
• Brakes - mechanism
  33
• 1 Repairing front brakes
  33
• 1.1 Assembly overview - front brakes FN 3
  33
• 1.2 Removing and installing brake pads or linings
  34
• 1.3 Removing and installing brake caliper
  37
• 2 Repairing rear brakes
  39
• 2.1 Assembly overview - rear brake CII 41
  39
• 2.2 Removing and installing brake pads or linings
  40
• 2.3 Removing and installing brake caliper
  43
• 3 Overview of electromechanical parking brake components
  46
• 3.1 Removing and installing control unit for electromechanical parking brake J540
  47
• 3.2 Removing and installing parking brake motor
  47
• 4 Assembly overview - brake pedal
  50
• 4.1 Assembly overview - brake pedal, left-hand drive
  50
• 4.2 Assembly overview - brake pedal, RHD
  52
• Brakes - hydraulics
  61
• 1 Repairing front brake calipers
  61
• 1.1 Assembly overview - brake caliper FN 3
  61
• 1.2 Removing and installing piston for brake caliper FN 3
  61
• 2 Repairing rear brake calipers
  65
• 2.1 Assembly overview - brake caliper CII 41
  65
• 2.2 Removing and installing brake caliper piston
  66
• 2.3 Pre-bleeding brake caliper
  68
• 3 Pressurised leak test
  69
• 3.1 Test prerequisites:
  69
• 4 Bleeding brake system
  70
• 4.1 Bleeding brake system with the brake filling and bleeding equipment VAS 5234
  70
• 4.2 Changing brake fluid
  72
• 5 Assembly overview - brake booster/brake master cylinder
  73
• 5.1 Assembly overview - brake booster/brake master cylinder (left-hand drive vehicle)
  73
• 5.2 Assembly overview - brake servo and brake master cylinder, RHD up to model year 2015
  75
• 5.3 Assembly overview - brake servo and brake master cylinder, RHD from model year 2016
  77
• 5.4 Vacuum pump for brake booster (vehicles with diesel engine)
  78
• 5.5 Vacuum pump for brake booster (vehicles with petrol engine)
  79
• 5.6 Checking brake booster vacuum system
  79
• 5.7 Checking non-return valve :
  83
• 5.8 Removing and installing vacuum sender G608
  83
• 5.9 Assembly overview - electric vacuum pump
  83
• 6 Removing and installing brake light switch F
  86
• 6.1 Removing and installing brake light switch F , left-hand drive
  86
• 6.2 Removing and installing brake light switch F , right-hand drive
  86
• 7 Removing and installing brake master cylinder
  88
• 7.1 Removing and installing brake master cylinder, LHD
  88
• 7.2 Removing and installing brake master cylinder, RHD
  90
• 8 Removing and installing brake booster
  95
• 8.1 Removing and installing brake booster, LHD
  95
• 8.2 Removing and installing brake booster, right-hand drive vehicle
  97
• 9 Brake lines
  107
• 9.1 Separating point on underbody
  107
• 9.2 Repairing brake lines
  107