Brake systems

Chapter overview

• Technical data
  1
• 1 Technical data, brakes
  1
• 1.1 Front brakes
  1
• 1.2 Rear brakes
  3
• 2 Brake test
  6
• 2.1 General
  6
• 2.2 Test for vehicles with front-wheel drive
  6
• 2.3 Test for vehicles with four-wheel drive via a viscous clutch
  6
• 2.4 Test for vehicles with four-wheel drive via a Haldex clutch
  7
• Anti-lock brake system
  8
• 1 Connect vehicle diagnosis, testing and information system VAS 5051 and select functions
  8
• 2 ABS and ABS/EDL Mark 04 GI
  10
• 2.1 General information on this ABS, ABS/EDL
  10
• 2.2 Notes for repair work on ABS, ABS/EDL
  10
• 2.3 Electrical/electronic components and fitting locations
  11
• 2.4 Fault display via warning lamps
  13
• 2.5 Assembly overview - hydraulic unit, brake servo/brake master cylinder
  14
• 2.6 Removing and installing control unit and hydraulic unit
  16
• 3 ABS Mark 20 IE up to model year 2000
  20
• 3.1 General information on this ABS
  20
• 3.2 Notes for repair work on ABS
  21
• 3.3 Electrical/electronic components and fitting locations
  22
• 3.4 Fault display via warning lamps
  25
• 3.5 Assembly overview - hydraulic unit/control unit
  26
• 3.6 Removing and installing control unit and hydraulic unit
  27
• 4 ABS Mark 20 IE as of model year 2001 and Mark 25 as of model year 2003
  33
• 4.1 General information on this ABS
  33
• 4.2 Notes for repair work on ABS
  34
• 4.3 Electrical/electronic components and fitting locations
  35
• 4.4 Fault display via warning lamps
  38
• 4.5 Assembly overview - hydraulic unit, brake servo/brake master cylinder
  39
• 4.6 Removing and installing control unit and hydraulic unit
  42
• 5 Removing and installing parts of ABS system on front and rear axle
  48
• 5.1 Removing and installing parts of ABS system on front axle
  48
• 5.2 Removing and installing parts of ABS system on rear axle
  53
• 6 Removing and installing parts of ESP system
  57
• 6.2 Removing and installing steering angle sender G85
  59
• 6.3 Removing and installing longitudinal acceleration sender G251
  61
• Brakes - mechanism
  62
• 1 Repairing front brakes
  62
• 1.1 Repairing front brakes, Teves/Ate up to model year 2000
  62
• 1.2 Removing and installing brake pads
  63
• 1.3 Repairing front brakes, FN3 brake caliper, model year 2001
  66
• 1.4 Removing and installing brake pads
  67
• 1.5 Repairing front brakes, FN3 brake caliper, as of model year 2002
  70
• 1.6 Removing and installing brake pads
  72
• 1.7 Repairing front brakes, FNR brake caliper as of model year 2001
  75
• 1.8 Removing and installing brake pads
  77
• 2 Repairing rear brakes
  80
• 2.1 Repairing 15" rear brakes
  80
• 2.2 Removing and installing brake pads
  82
• 2.3 Repairing 16" rear brakes
  84
• 2.4 Removing and installing brake pads
  86
• 2.5 Adjusting handbrake
  89
• 3 Assembly overview - handbrake lever
  91
• 3.1 Removing and installing front handbrake cable
  91
• 3.2 Removing and installing centre handbrake cable
  93
• 3.3 Removing and installing rear handbrake cable
  94
• 4 Assembly overview - brake pedal up to model year 2000
  96
• 4.1 Removing and installing brake pedal
  97
• 5 Assembly overview - brake pedal as of model year 2001
  98
• 5.1 Separating brake pedal from brake servo
  99
• 5.2 Removing and installing brake pedal
  100
• 6 Removing and installing brake light switch F and brake pedal switch F47
  102
• 6.1 Brake light switch to week 45 of 2006
  102
• 6.2 Brake light switch from week 45 of 2006
  104
• Brakes - hydraulics
  105
• 1 Repairing front brake calipers
  105
• 1.1 Repairing Teves/Ate brake calipers and FN3 brake calipers
  105
• 1.2 Removing and installing piston for brake caliper
  106
• 1.3 Repairing front brake calipers, FNR brake calipers
  107
• 1.4 Removing and installing piston for FNR brake calipers
  108
• 2 Repairing rear brake caliper
  111
• 2.1 Removing and installing piston for rear brake caliper
  112
• 2.2 Pre-bleeding brake caliper
  114
• 3 Assembly overview: brake pressure regulator, delay dependent
  115
• 3.1 Checking brake pressure regulator, delay dependent
  115
• 4 Pressure leak test
  116
• 4.1 Test prerequisites
  116
• 5 Bleeding brake system
  117
• 5.2 Changing brake fluid (every 2 years)
  119
• 6 Assembly overview: Brake servo/brake master cylinder up to model year 2000
  120
• 6.1 Checking non-return valve
  121
• 7 Assembly overview: Brake servo/brake master cylinder as of model year 2001 . . .
  122
• 8.1 Removing and installing brake pressure sender 1 G201 and brake pressure sender 2 G214
  125
• 8.2 Vehicles with mechanical brake assist system
  126
• 9 Removing and installing brake master cylinder
  127
• 9.1 Removing
  127
• 9.2 Installing
  128
• 10 Removing and installing brake master cylinder, right-hand drive vehicles
  129
• 10.1 Removing
  129
• 10.2 Installing
  130
• 11 Removing and installing brake servo
  131
• 11.1 Removing
  131
• 11.2 Installing
  132
• 12 Removing and installing brake servo, right-hand drive vehicles
  134
• 12.1 Removing
  134
• 12.2 Installing
  134
• 13 Repairing brake lines
  136
• 13.1 Assembly overview - flanging tool
  138
• 13.2 Work instructions
  138