Brake systems

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Brakes ▸ 09.99
  1
• 1.2 Brakes 10.99 ▸
  5
• 2 Brake test
  8
• 2.1 General
  8
• 2.2 Test for vehicles with front-wheel drive
  8
• Anti-lock brake system
  9
• 1 Anti-lock brake system (ABS) ITT Mark 04 GI
  9
• 1.1 General information on this ABS
  9
• 1.2 Notes for repair work on the ABS
  9
• 2 Assembly overview - hydraulic unit, brake servo/brake master cylinder
  11
• 2.1 Connecting brake lines from tandem brake master cylinder to hydraulic unit
  12
• 2.2 Removing and installing control unit and hydraulic unit
  12
• 3.1 General information on this ABS
  16
• 3.2 Distinguishing features of ABS ITT Mark 20 GI/ITT Mark 20 IE
  17
• 3.3 Notes for repairs on ABS, ABS/EDL
  17
• 4 Assembly overview - hydraulic unit, brake servo/brake master cylinder
  19
• 4.1 Removing and installing control unit and hydraulic unit
  19
• 5 Removing and installing parts of ABS system on front and rear axles
  23
• 5.1 Removing and installing parts of ABS system on front axle, VW I brake caliper
  23
• 5.2 Removing and installing parts of ABS system on front axle, VW II brake caliper
  26
• 6 Removing and installing parts of ESP system
  43
• 6.1 Removing and installing yaw rate sender G202
  43
• 6.2 Removing and installing lateral acceleration sender G200
  44
• 6.3 Removing and installing steering angle sender G85
  45
• Brakes - mechanism
  46
• 1 Repairing front brakes
  46
• 1.1 Repairing front brakes, VW I and VW II brake caliper
  46
• 1.2 Removing and installing brake pads, up to 01.96
  49
• 1.3 Removing and installing brake pads, from 01.96
  51
• 1.4 Repairing Girling/Lucas front brakes
  53
• 1.5 Removing and installing brake pads, Girling/Lucas brake caliper
  55
• 2 Repairing rear brakes, drum brakes
  58
• 2.1 Removing and installing brake drum, up to 09.99
  58
• 2.2 Removing and installing brake drum, as of 10.99
  60
• 2.3 Releasing brake shoe adjustment
  61
• 2.4 Repairing brake drum
  61
• 2.5 Removing and installing brake shoes
  63
• 2.6 Adjusting handbrake
  64
• 3 Repairing rear brakes (disc brakes)
  66
• 3.1 Removing and installing disc brake
  66
• 3.2 Removing and installing brake pads
  69
• 3.3 Adjusting handbrake
  72
• 4 Removing and installing handbrake cable (drum brakes)
  73
• 5 Removing and installing handbrake cable (disc brakes)
  75
• 6 Assembly overview - handbrake lever
  77
• 7 Assembly overview - brake pedal
  78
• 7.1 Separating brake pedal from brake servo
  78
• 7.2 Removing and installing brake pedal
  79
• 7.3 Adjusting brake light switch
  80
• Brakes - hydraulics
  82
• 1 Repairing front brake caliper, VW I and VW II brake caliper
  82
• 1.1 Removing and installing piston for front brake caliper
  82
• 2 Repairing Girling/Lucas front brake caliper
  85
• 2.1 Removing and installing piston for front brake caliper
  85
• 3 Repairing rear brake caliper
  88
• 3.1 Removing and installing piston for rear brake caliper
  89
• 3.2 Pressure leak test
  91
• 4 Assembly overview - brake pressure regulator
  92
• 5 Checking and adjusting brake pressure regulator
  93
• 5.1 Checking and adjusting pressure
  93
• 5.2 Load dependent brake pressure regulator specifications
  93
• 6 Bleeding brake system
  95
• 6.2 Bleeding brake system without brake filling and bleeding unit
  96
• 6.3 Changing brake fluid
  96
• 7 Assembly overview - brake servo/ brake master cylinder
  97
• 7.1 Removing and installing vacuum pump for brake servo (diesel vehicles)
  98
• 7.2 Checking non-return valve
  99
• 8.1 Removing and installing brake pressure sender
  101
• 9 Removing and installing brake master cylinder
  103
• 9.1 Removing
  103
• 9.2 Installing
  103
• 10 Removing and installing brake servo
  104
• 10.1 Removing
  104
• 10.2 Installing
  105