Brake systems

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Brake PR number correspondence
  1
• 2 Technical data
  2
• 2.1 Brake technical data
  2
• 3 Brake control
  4
• 3.1 General information
  4
• 3.2 Check
  4
• Anti-lock brake system
  5
• 1 General information on the anti-lock braking system (ABS)
  5
• 1.1 Information on repair works on the ABS
  5
• 1.2 Vehicle diagnostic and service information system
  6
• 2 Electrical/electronic components and installing locations
  8
• 2.1 ABS
  8
• 2.2 ABS/ESP
  9
• 3 Hydraulic unit, brake servo/master cylinder
  11
• 3.1 Hydraulic unit, brake servo/master cylinder - assembly overview
  11
• 3.2 Command unit for hydraulic unit - remove and install
  12
• 3.3 Hydraulic unit connections
  16
• 4 Sensors
  18
• 4.1 Front axle speed sensor - assembly overview
  18
• 4.2 Front axle speed sensor - remove and install
  19
• 4.3 ABS system components on rear axle (vehicles with drum brakes) - assembly overview
  19
• 4.4 Speed sensor on rear axle (drum brake) - remove and install
  21
• 4.5 Steering angle sensor G85 - remove and install
  21
• Brakes - mechanism
  23
• 1 Front wheel brake
  23
• 1.1 Front wheel brake - assembly overview
  23
• 1.2 Brake pads - remove and install
  24
• 1.3 Brake caliper - remove and install
  26
• 1.4 Brake disc - check (disc knocking)
  29
• 2.1 Rear wheel brake (One shot (wedge) system) - assembly overview
  30
• 2.2 Brake drum (One shot (wedge) system) - position
  32
• 2.3 Brake shoes (One shot - wedge - system) - remove and install
  32
• 3.1 Rear wheel brake (Micrometric system) - assembly overview
  36
• 3.2 Brake shoes (Micrometric system) - remove and install
  37
• 4 Handbrake
  46
• 4.1 Handbrake - assembly overview
  46
• 4.2 Handbrake cable (drum brake) - remove and install
  47
• 4.3 Handbrake (One shot (wedge) system) - adjust
  50
• 4.4 Handbrake (Micrometer system) - adjust
  52
• 5 Brake pedal
  54
• 5.1 Brake pedal - assembly overview
  54
• 5.2 Brake pedal - separate
  55
• 5.3 Fasten brake pedal to brake servo
  56
• 5.4 Brake pedal - remove and install
  56
• 5.5 Support - remove and install
  56
• Brakes - hydraulics
  58
• 1 Front brake caliper
  58
• 1.1 Front brake caliper - assembly overview
  58
• 1.2 Plunger for front brake caliper - remove and install
  58
• 2 Brake servo/Brake master cylinder
  61
• 2.1 Brake servo/ brake cylinder - assembly overview
  61
• 2.2 Brake light switch - remove and install
  62
• 2.3 Brake servo - remove and install
  63
• 3 Vacuum system
  67
• 3.1 Vacuum pump - assembly overview
  67
• 3.2 Retaining valve - test
  68
• 3.3 Vacuum system - check
  68
• 3.4 Electric vacuum pump - remove and install
  72
• 3.5 Brake servo pressure sensor - remove and install
  73
• 4 Hydraulic system
  74
• 4.1 General brake fluid recommendations
  74
• 4.2 Bleed the brake system
  74
• 4.3 Later bleeding
  76
• 4.4 Tightness assessment
  76