Brake systems

Chapter overview

• Technical data
  1
• 1 Technical Data
  1
• 1.1 Front wheel brake - FS II
  1
• 1.2 Rear wheel disc brake
  2
• 1.3 Rear wheel drum brake
  3
• 1.4 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
  19
• 7 ABS system components on the front and rear axles - remove and install
  21
• 7.1 Remove and install the ABS system components from the front axle
  21
• 7.2 Bosch front speed sensor cables - remove and install
  22
• Brakes - mechanism
  33
• 1 Front wheel brake disk - repair
  33
• 1.1 FS II Disc brake cylinder - repair
  33
• 1.2 Brake pads, FS II brake calipers - remove and install
  34
• 1.3 FS II brake caliper - remove and install
  36
• 1.4 Brake disc - remove and install
  38
• 1.5 Brake disk (knocking) - check
  39
• 1.6 Brake disc - check
  40
• 2 Rear wheel drum brake (One-Shot System) - repair
  44
• 2.1 Rear wheel brake - remove and install
  44
• 2.2 Brake drum - repair
  46
• 2.3 Brake shoes - remove and install
  47
• 3 Rear wheel brake (Micrometric System) - repair
  51
• 3.1 Rear wheel brake (Micrometric system) - assembly overview
  51
• 3.2 Brake shoes (Micrometric system) - remove and install
  52
• 4 Rear wheel disc brake - repair
  60
• 4.1 Brake pads - remove and install
  62
• 4.2 Brake caliper - remove and install
  65
• 5 Handbrake - assembly overview
  67
• 5.1 Handbrake lever - remove and install
  68
• 6 Handbrake cable - repair
  69
• 6.1 Handbrake cable (drum brakes) - assembly overview
  69
• 6.2 Handbrake cable (disc brakes) - assembly overview
  70
• 6.3 Handbrake cable (drum brake) - remove and install
  70
• 6.4 Handbrake cable (disc brake) - remove and install
  73
• 6.5 Handbrake (drum brake) - adjust
  75
• 6.6 Handbrake (disc brake) - adjust
  76
• 6.7 Handbrake switch - remove and install
  77
• 7 Brake pedal - assembly overview
  79
• 7.1 Servo brake pedal - separate
  79
• 7.2 Pedal set - remove and install
  80
• 7.3 Brake pedal - remove and install
  81
• 7.4 Brake light sensor F - remove and install
  82
• Brakes - hydraulics
  83
• 1 FS II front brake caliper - repair
  83
• 1.1 Plunger for front brake caliper - remove and install
  84
• 2 Rear brake caliper - repair
  86
• 2.1 Plunger for rear brake caliper - remove and install
  87
• 2.2 Tightness assessment
  89
• 3 Vehicles without braking power adjustment - assembly overview
  90
• 4 Vehicles without braking power adjustment - general overview of assembly
  91
• 4.1 Braking power adjustment - adjust
  92
• 4.2 Braking power adjustment - check
  92
• 5 Bleed the brake system
  94
• 5.1 Bleed the brake system with the filling and bleeding equipment
  94
• 5.2 Brake system, (vehicles with ABS) - bleed when the tank is empty
  95
• 6 Assembly overview: Brake servo/brake master cylinder
  97
• 6.1 Flexible vacuum tube
  98
• 7 Brake servo - remove and install
  99
• 7.1 Remove
  100
• 7.2 Install
  102
• 8 Vacuum system - Check
  103
• 8.1 Test instructions
  103
• 8.2 Servo brake vacuum measurement device VAS 6721 - connect
  104
• 8.3 Vacuum generation control
  105
• 8.4 Leak control
  105
• 8.5 Vacuum generation with the manual vacuum pump VAS 6213
  107
• 8.6 Retention valve - check
  107