Brake systems

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Front wheel brake - FS II
  1
• 1.2 Rear wheel brake
  3
• 1.3 Specifications
  3
• Anti-lock brake system
  5
• 1 General information on the anti-lock braking system (ABS)
  5
• 2 Information on repair works on the ABS
  6
• 4 Electrical/electronic components and installing locations
  9
• 4.1 ABS Bosch
  9
• 5 Hydraulic unit, servo brake/master cylinder - Bosch ABS assembly overview of assembly
  11
• 5.1 Hydraulic unit connections
  13
• 5.2 Command unit for hydraulic unit - remove and install
  14
• 6 Fault indication via control lights
  20
• 7 ABS system components on the front and rear axles - remove and install
  22
• 7.1 Remove and install the ABS system components from the front axle
  22
• 7.2 Bosch front speed sensor cables - remove and install
  23
• 7.3 ABS system components on the front axle - remove and install
  28
• 8 Rear rotor - remove and install
  35
• 8.1 Removal
  35
• 8.2 Installation
  36
• Brakes - mechanism
  37
• 1 Front wheel brake disk - repair
  37
• 1.1 FS II Disc brake cylinder - repair
  37
• 1.2 Brake pads, FS II brake calipers - remove and install
  38
• 1.3 FS II brake caliper - remove and install
  40
• 1.4 Brake disc - remove and install
  42
• 1.5 Brake disk (knocking) - check
  43
• 1.6 Brake disc - check
  44
• 2 Rear wheel drum brake - repair
  48
• 2.1 Rear wheel brake - remove and install
  48
• 2.2 Brake drum - repair
  50
• 2.3 Brake shoes - remove and install
  51
• 2.4 Brake shoes (only Saveiro from 2010) - remove and install
  55
• 3 Handbrake - assembly overview
  58
• 3.1 Handbrake lever - remove and install
  59
• 4 Handbrake cable - repair
  60
• 4.1 Handbrake cable - assembly overview
  60
• 4.2 Handbrake cable - remove and install
  60
• 4.3 Handbrake - adjust
  63
• 4.4 Handbrake switch - remove and install
  64
• 5 Brake pedal - assembly overview
  66
• 5.1 Servo brake pedal - separate
  66
• 5.2 Pedal set - remove and install
  67
• 5.3 Brake pedal - remove and install
  68
• 5.4 Brake pedal switch F47 - remove and install
  69
• Brakes - hydraulics
  71
• 1 FS II front brake caliper - repair
  71
• 1.1 Plunger for front brake caliper - remove and install
  72
• 2 Vehicles without braking power adjustment - assembly overview
  74
• 3 Vehicles without braking power adjustment - general overview of assembly
  75
• 3.1 Braking power adjustment - adjust
  76
• 3.2 Braking power adjustment - check
  76
• 4 Bleed the brake system
  78
• 4.1 Bleed the brake system with the filling and bleeding equipment
  78
• 4.2 Brake system, (vehicles with ABS) - bleed when the tank is empty
  79
• 5 Assembly overview: Brake servo/brake master cylinder
  81
• 5.1 Flexible vacuum tube
  82
• 6 Brake cylinder - remove and install
  83
• 6.1 Vehicles with/without ABS
  83
• 7 Brake servo - remove and install
  85
• 7.1 Removal
  86
• 7.2 Installation
  87
• 8 Vacuum system - Check
  89
• 8.1 Test instructions
  89
• 8.2 Servo brake vacuum measurement device VAS 6721 - connect
  90
• 8.3 Vacuum generation control
  91
• 8.4 Leak control
  91
• 8.5 Vacuum generation with the manual vacuum pump VAS 6213
  93
• 8.6 Retention valve - check
  93