Brake systems

Chapter overview

• Technical data
  1
• 1 Brake allocation via PR No
  1
• 1.1 Example of a vehicle data sticker
  1
• 1.2 Front brakes
  1
• 1.3 Rear brakes (disc brakes)
  1
• 2 Technical data
  3
• 2.1 Brake master cylinder and brake servo
  3
• 2.2 Front brakes
  3
• 2.3 Rear brakes
  5
• 3 Brake test
  8
• 3.1 General
  8
• 3.2 Test
  8
• Anti-lock brake system
  9
• 1 General notes for anti-lock brake system (ABS)
  9
• 2 Notes for repair work on the ABS
  10
• 3 Connecting VAS 5051 and selecting functions
  11
• 4 Electrical/electronic components and fitting locations
  13
• 5 Fault display via warning lamps
  15
• 6 Assembly overview - hydraulic unit, brake servo/brake master cylinder
  18
• 6.1 ABS MK 25 to week 48/06
  18
• 6.2 ABS MK 25 E1 from week 48/06
  24
• 7 Removing and installing parts of ABS system on front and rear axle
  31
• 7.1 Removing and installing speed sensor on front axle
  31
• 7.2 Removing and installing parts of ABS system on rear axle
  32
• 7.3 Removing and installing speed sensor on rear axle
  33
• 8 Removing and installing parts of ESP system
  34
• 8.1 Removing and installing ESP sensor unit G419
  34
• 8.2 Removing and installing steering angle sender G85
  35
• Brakes - mechanism
  36
• 1 Repairing front brakes
  36
• 1.1 Repairing front brakes, FN 3 brake caliper (16")
  36
• 1.2 Removing and installing brake pads/linings
  37
• 1.3 Removing and installing brake caliper
  41
• 1.4 Repairing front brake, Brembo 17" brake caliper (1LC)
  44
• 1.5 Removing and installing brake pads/linings
  46
• 1.6 Removing and installing brake caliper
  49
• 1.7 Repairing front brake, Brembo 17" brake caliper (1LE)
  51
• 1.8 Removing and installing brake pads/linings
  52
• 1.9 Removing and installing brake caliper
  54
• 1.10 Repairing front brake, Brembo 18" brake caliper
  56
• 1.11 Removing and installing brake pads/linings
  58
• 1.12 Removing and installing brake caliper
  61
• 1.13 Repairing front brake, Brembo 18" brake caliper Plus
  63
• 1.14 Removing and installing brake pads/linings
  64
• 1.15 Removing and installing brake caliper
  66
• 2 Repairing rear brakes
  69
• 2.1 Repairing rear brakes, brake caliper FN 44
  69
• 2.2 Removing and installing brake pads/linings
  70
• 2.3 Removing and installing brake caliper
  75
• 2.4 Removing and installing brake shoes
  78
• 2.5 Repairing rear brakes, Brembo 17" brake caliper (1KF)
  79
• 2.6 Removing and installing brake pads/linings
  81
• 2.7 Removing and installing brake caliper
  84
• 2.8 Removing and installing brake shoes
  86
• 2.9 Repairing rear brakes, Brembo 17" brake caliper (1KQ)
  87
• 2.10 Removing and installing brake pads/linings
  89
• 2.11 Removing and installing brake caliper
  92
• 2.12 Removing and installing brake shoes
  93
• 2.13 Repairing rear brakes, 18" brake caliper Plus
  94
• 2.14 Removing and installing brake pads/linings
  96
• 2.15 Removing and installing brake caliper
  98
• 2.16 Removing and installing brake shoes
  100
• 2.17 Adjusting parking brake
  101
• 3 Assembly overview - foot-operated parking brake
  103
• 3.1 Parking brake pedal
  103
• 3.2 Transfer module
  104
• 3.3 Rear brake cable
  104
• 3.4 Removing and installing parking brake pedal
  105
• 4 Brake cables
  107
• 4.1 Removing and installing rear brake cables
  107
• 4.2 Removing and installing front brake cable
  108
• 5 Assembly overview - brake pedal (LHD)
  110
• 5.1 Separating brake pedal from brake servo
  110
• 5.2 Removing and installing brake light switch F and brake pedal switch F47
  112
• Brakes - hydraulics
  114
• 1 Repairing front brake calipers
  114
• 1.1 Repairing FN 3 brake calipers
  114
• 1.2 Removing and installing piston for brake caliper FN 3
  114
• 1.3 Repairing Brembo brake calipers (17", 18" and 18" Plus)
  117
• 1.4 Removing and installing Brembo brake caliper piston (17", 18" and 18" Plus)
  120
• 2 Repairing rear brake calipers
  123
• 2.1 Repairing FN 44 brake calipers
  123
• 2.2 Removing and installing piston for FN 44 brake caliper
  123
• 2.3 Repairing Brembo brake calipers (17"and 18" Plus)
  126
• 2.4 Removing and installing rear brake caliper piston
  129
• 3 Pressurised leak test
  132
• 4 Bleeding brake system
  133
• 4.2 Changing brake fluid
  135
• 5 Assembly overview - brake servo/brake master cylinder
  136
• 5.2 Removing and installing brake pressure sender G201
  138
• 6 Brake servo vacuum supply
  139
• 6.1 Overview - vacuum pump for brake servo (diesel vehicles)
  139
• 6.2 Assembly overview - vacuum pump for brakes V192
  139
• 6.3 Checking non-return valve
  141
• 7 Removing and installing brake master cylinder
  142
• 7.1 Removing
  142
• 7.2 Installing
  142
• 8 Removing and installing brake servo
  144
• 8.1 Removing
  144
• 8.2 Installing
  145
• 9 Repairing brake lines
  146
• 9.1 Assembly overview - flanging tool
  146
• 9.2 Work instructions
  147