Brake systems

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Brake PR number correspondence
  1
• 1.2 Brake technical data
  2
• Anti-lock Braking System (ABS)
  3
• 1 Information on repair works on the ABS
  3
• 3 General information on the Bosch 5.7 antilock braking system (ABS)
  5
• 4 General information on the Bosch 8.0 antilock braking system (ABS)
  6
• 5 General information on the Bosch 8.2 antilock braking system (ABS)
  7
• 6 Electrical/electronic components and installing locations
  8
• 6.1 ABS Bosch 5.7
  8
• 6.2 ABS Bosch 8.0 (ABS/ESP)
  9
• 6.3 ABS Bosch 8.2
  10
• 7.1 Hydraulic unit connections
  15
• 7.2 Control unit and hydraulic unit - remove and install
  15
• 7.3 ABS control unit J104 from the ABS hydraulic unit N55 - Remove and install
  19
• 7.4 Brake pressure Sensor 1 G201 - remove and install
  21
• 8.1 Hydraulic unit connections
  25
• 8.2 ABS control unit J104 on the ABS hydraulic unit N55 - remove and install
  25
• 9 Fault indication via control lamps
  34
• 9.1 Control lamps
  34
• 10 ABS system components on the front and rear axles - remove and install
  36
• 10.1 ABS system components on the front axle - remove and install
  36
• 10.2 Bosch 5.7 front speed sensor cables - remove and install
  37
• 10.3 Bosch 8.0 / 8.2 front speed sensor cables - remove and install
  40
• 11 ESP system components - remove and install
  45
• 11.2 Steering angle sensor G85 - remove and install
  46
• Brakes - Mechanical system
  47
• 1 Front wheel brake - repair
  47
• 1.1 Front wheel brake (FS ll) - assembly overview
  47
• 1.2 Brake pads (FS II) - remove and install
  48
• 1.3 Brake caliper (FS II) - remove and install
  50
• 1.4 Front wheel brake (FS ll) - Assembly overview
  53
• 1.5 Brake pads (FS III) - remove and install
  55
• 1.6 Brake caliper (FS III) - remove and install
  57
• 1.7 Brake disc with visual check - check
  59
• 2 Rear wheel brake (drum brake) - repair
  62
• 2.1 Brake drum - Assembly overview
  62
• 2.2 Brake shoes - remove and install
  63
• 3 Parking brake - Assembly overview
  66
• 3.1 Parking brake cable (drum brake) - remove and install
  66
• 3.2 Parking brake - adjust
  68
• 4 Brake pedal - Assembly overview
  70
• 4.1 Pedal set - remove and install
  70
• 4.2 Brake pedal - remove and install
  72
• 4.3 Brake pedal switch F47 - remove and install
  74
• Brakes - Hydraulic system, servo brake
  76
• 1 Front brake caliper (FS II) - repair
  76
• 1.1 Plunger for front brake caliper - remove and install
  77
• 2 Front brake caliper, brake caliper (FS II) - repair
  79
• 2.1 Front brake caliper plunger - remove and install
  79
• 3 Braking power adjustment - Assembly overview
  82
• 3.1 Brake pressure regulator - adjust
  82
• 3.2 Brake pressure regulator - check
  83
• 4 Brake system - bleed
  85
• 4.1 Brake system - Bleed with brake replenishment and bleed equipment
  85
• 4.2 Brake system - Bleed without brake replenishment and bleed equipment
  86
• 4.3 Brake system with ABS/EDS/ASR - Bleed when the reservoir is empty
  86
• 5 Brake booster/brake master cylinder - Assembly overview
  88
• 5.1 Servo brake vacuum pump (diesel vehicles) - remove and install
  89
• 5.2 Check valve - check
  91
• 6 Brake cylinder - remove and install
  92
• 6.1 Removal
  92
• 6.2 Installation
  93
• 7 Servo brake - remove and install
  94
• 7.1 Removal
  94
• 7.2 Installation
  96