Brake systems

Chapter overview

• Technical data
  1
• 1 Brake allocation via PR No
  1
• 1.1 Front brakes
  1
• 1.2 Rear brakes
  2
• 2 Technical data for brakes
  3
• 2.1 Brake master cylinder and brake booster
  3
• 2.2 Front brakes
  3
• 2.3 Rear brakes
  4
• 3 Brake test
  6
• 3.1 General
  6
• 3.2 Test for vehicles with front-wheel drive
  6
• Anti-lock brake system
  7
• 1 General notes for anti-lock brake system (ABS)
  7
• 1.1 Bosch 8.2 and 9.0
  7
• 2 Notes for repair work on anti-lock brake system
  9
• 3 Connecting VAS 5051 and selecting functions
  10
• 4 Electrical/electronic components and locations
  12
• 4.1 Bosch 8.2; 9.0 ABS
  12
• 4.2 Bosch 8.2i; 9.0i ABS/EDL/TCS/ESP
  13
• 5 Fault display via warning lamps
  15
• 6 Assembly overview - hydraulic unit, brake booster/brake master cylinder
  17
• 6.1 Bosch 8.2; 9.0 ABS, LHD vehicles
  17
• 6.2 Bosch 8.2; 9.0 ABS, RHD vehicles
  26
• 6.3 Bosch 8.2i; 9.0i ABS/EDL/TCS/ESP, LHD vehicles
  35
• 6.4 Bosch 8.2i; 9.0i ABS/EDL/TCS/ESP, RHD vehicles
  46
• 7 Removing and installing parts of ABS system on front and rear axle
  56
• 7.1 Removing and installing parts of ABS system on front axle
  56
• 7.3 Removing and installing parts of anti-lock brake system on rear axle (disc brakes)
  59
• 8 Removing and installing parts of ESP system
  62
• 8.2 Removing and installing steering angle sender G85
  62
• Brakes - mechanism
  63
• 1 Repairing front brakes
  63
• 1.1 Repairing front brakes, FS III brake caliper
  63
• 1.2 Removing and installing brake pads, brake caliper FS III
  64
• 1.3 Removing and installing brake caliper FS III
  66
• 1.4 Repairing front brakes, FN 3 brake caliper
  68
• 1.5 Removing and installing brake pads, brake caliper FN 3
  70
• 1.6 Removing and installing brake caliper FN 3
  72
• 2 Repairing rear brakes (drum brakes)
  75
• 2.1 Removing and installing rear brakes
  76
• 2.2 Resetting brake
  77
• 2.3 Repairing rear brakes
  77
• 2.4 Removing and installing brake shoes
  79
• 3 Repairing rear brakes (disc brakes)
  82
• 3.1 Removing and installing brake pads/linings
  83
• 3.2 Removing and installing brake caliper
  86
• 4 Assembly overview - handbrake lever
  88
• 4.1 Removing and installing handbrake cable (drum brakes)
  89
• 4.2 Adjusting handbrake
  91
• 4.3 Removing and installing handbrake cable (disc brakes)
  92
• 4.4 Adjusting handbrake
  94
• 5 Assembly overview - brake pedal
  96
• 5.1 Assembly overview - brake pedal, left-hand drive
  96
• 5.2 Assembly overview - brake pedal, right-hand drive
  99
• Brakes - hydraulics
  103
• 1 Repairing front brake calipers
  103
• 1.1 Repairing FS III brake calipers
  103
• 1.2 Removing and installing brake caliper FS III
  103
• 1.3 Repairing FN 3 brake calipers
  105
• 1.4 Removing and installing brake caliper piston FN 3
  106
• 2 Repairing rear brake calipers
  110
• 2.1 Removing and installing rear brake caliper piston
  110
• 3 Pressurised leak test
  113
• 3.1 Test prerequisites:
  113
• 4 Bleeding brake system
  114
• 4.1 Bleeding brake system with brake filling and bleeding equipment VAS 5234
  114
• 4.2 Changing brake fluid
  116
• 5 Assembly overview - brake booster/brake master cylinder
  117
• 5.1 Assembly overview - brake booster/brake master cylinder (left-hand drive vehicle)
  117
• 5.3 Vacuum pump for brake booster (vehicles with diesel engine)
  120
• 5.4 Checking brake booster vacuum system
  120
• 5.5 Checking non-return valve
  124
• 5.6 Vacuum pump for brakes V192
  124
• 5.7 Removing and installing brake booster pressure sensor G294
  126
• 5.8 Removing and installing brake light switch F , left-hand drive
  127
• 5.9 Removing and installing brake light switch F , right-hand drive
  127
• 6 Removing and installing brake master cylinder
  129
• 6.1 Removing and installing brake master cylinder, left-hand drive
  129
• 6.2 Removing and installing brake master cylinder, right-hand drive vehicle
  130
• 7 Removing and installing brake booster
  134
• 7.1 Removing and installing brake booster, left-hand drive
  134
• 7.2 Removing and installing brake booster, right-hand drive vehicle
  137
• 8 Repairing brake lines
  144
• 8.1 Assembly overview - flanging tool
  144
• 8.2 Work instructions
  145