Brake systems

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Lupo 3 L
  1
• 1.2 Lupo FSI
  2
• 1.3 Lupo GTI
  3
• 2 Brake test
  4
• 2.1 General
  4
• 2.2 Test
  4
• Anti-lock brake system
  5
• 1 ABS Mark 30 IE and ABS/EDL/TCS/ESP Mark 20 IE anti-lock brake system
  5
• 1.1 ABS Mark 30 IE anti-lock brake system
  5
• 1.2 ABS/EDL/TCS/ESP Mark 20 IE anti-lock brake system
  6
• 2 Connecting VAS 5051 and selecting functions
  8
• 3 Electrical and electronic components and locations (ABS, ABS/EDL)
  10
• 4 Faults displayed by warning lamps for ABS, ABS/EDL
  12
• 5 Electrical and electronic components and locations (ABS/EDL/TCS/ESP)
  13
• 6 Faults displayed by warning lamps, ABS/EDL/TCS/ESP
  16
• 7 Assembly overview - hydraulic unit, brake servo/brake master cylinder
  18
• 7.1 Assembly overview, ABS Mark 30 IE - hydraulic unit, brake servo/brake master cylinder
  18
• 7.2 Removing and installing control unit and hydraulic unit, ABS MARK 30 IE
  21
• 8 Removing and installing parts of ABS system on front and rear axle
  32
• 8.1 Removing and installing parts of ABS system on front axle, Lupo 3 L
  32
• 8.2 Removing and installing parts of ABS system on rear axle, Lupo 3 L
  35
• 9 Removing and installing parts of ESP system
  46
• 9.2 Removing and installing steering angle sender G85
  47
• Brakes - mechanism
  48
• 1 Repairing front brakes
  48
• 1.1 Repairing front brakes, FS I - AL brake calipers, Lupo 3 L
  48
• 1.2 Removing and installing brake pads
  49
• 1.3 Removing and installing AL brake caliper FS I
  51
• 1.4 Repairing front brakes, Lucas brake caliper, Lupo FSI and Lupo GTI
  53
• 1.5 Removing and installing brake pads, Lucas brake caliper
  54
• 1.6 Removing and installing Lucas brake calipers
  56
• 2 Repairing rear brakes, drum brakes
  58
• 2.1 Removing and installing rear brakes, Lupo 3 L
  58
• 2.2 Releasing brake shoe adjustment
  60
• 2.3 Repairing rear brakes
  61
• 2.4 Removing and installing brake shoes
  62
• 3 Repairing rear brakes (disc brakes)
  65
• 3.1 Repairing rear brakes, Lupo FSI and Lupo GTI
  65
• 3.2 Removing and installing brake pads
  66
• 3.3 Removing and installing brake caliper
  69
• 4 Assembly overview - handbrake lever
  71
• 4.1 Removing and installing handbrake cable (drum brakes)
  71
• 4.2 Adjusting handbrake (drum brakes)
  73
• 4.3 Removing and installing handbrake cable (disc brakes)
  74
• 4.4 Adjusting handbrake (disc brakes)
  76
• 5 Assembly overview - brake pedal
  77
• 5.1 Vehicles with mechanical steering, Lupo 3 L
  77
• 5.2 Vehicles with electromechanical servo steering, Lupo 3 L
  82
• 5.3 Vehicles with mechanical and hydraulic steering, Lupo FSI and Lupo GTI
  89
• Brakes - hydraulics
  94
• 1 Repairing front brake calipers
  94
• 1.1 FS I - AL brake caliper, Lupo 3 L
  94
• 1.2 Removing and installing front brake caliper piston
  94
• 1.3 Lucas brake caliper, Lupo FSI and Lupo GTI
  97
• 1.4 Removing and installing front brake caliper piston
  98
• 2 Repairing rear brake caliper
  101
• 2.1 Removing and installing piston for rear brake caliper
  102
• 2.2 Pressure leak test
  104
• 3 Bleeding brake system
  105
• 3.2 Bleeding brake system without brake filling and bleeding appliance
  107
• 3.3 Changing brake fluid
  107
• 4 Assembly overview - brake master cylinder/brake servo
  108
• 4.1 Checking non-return valve :
  109
• 4.2 Removing and installing brake pressure switch F270
  109
• 5.1 Removing and installing brake pressure sender from brake master cylinder
  112
• 6 Removing and installing brake master cylinder
  114
• 6.1 Removing
  114
• 6.2 Installing
  114
• 7 Removing and installing brake servo
  115
• 7.1 Removing
  115
• 7.2 Installing
  116
• 8 Repairing brake lines
  117
• 8.1 Assembly overview - flanging tool
  119
• 8.2 Work instructions
  119