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
  1
• 2 Technical data
  3
• 2.1 Brake master cylinder and brake servo
  3
• 2.2 Front brakes
  3
• 2.3 Rear brakes
  4
• 3 Brake test
  5
• 3.1 General
  5
• 3.2 Testing vehicles with no electric differential lock
  5
• 3.3 Testing vehicles with electric differential lock
  5
• 3.4 Testing the electromechanical parking brake
  5
• Anti-lock brake system
  7
• 1 General notes for anti-lock brake system (ABS)
  7
• 2 Notes for repair work on the ABS
  8
• 3 Connecting VAS 5051 and selecting functions
  9
• 4 Electrical/electronic components and locations
  11
• 5 Assembly overview - hydraulic unit
  13
• 5.1 ABS MK 25
  13
• 6 Removing and installing parts of ABS system on front and rear axle
  23
• 6.1 Removing and installing speed sensor on front axle
  23
• 6.2 Removing and installing parts of ABS system on rear axle
  24
• 6.3 Removing and installing speed sensor on rear axle
  25
• 7 Removing and installing parts of ESP system
  26
• 7.1 Removing and installing ESP sensor unit G419
  26
• 7.2 Removing and installing steering angle sender G85
  27
• Brakes - mechanism
  28
• 1 Repairing front brakes
  28
• 1.1 Assembly overview - front brake, Brembo 17"
  28
• 1.2 Removing and installing brake pads or linings
  29
• 1.3 Removing and installing brake caliper
  32
• 1.4 Assembly overview - front brake, Brembo 18"
  34
• 1.5 Removing and installing brake pads/linings
  35
• 1.6 Removing and installing brake caliper
  39
• 2 Repairing rear brakes
  42
• 2.1 Assembly overview - rear brake caliper, 17"
  42
• 2.2 Removing and installing brake pads or linings
  44
• 2.3 Removing and installing brake caliper
  46
• 2.4 Removing and installing brake shoes
  48
• 2.5 Adjusting air gap
  49
• 3 Repairing thread in brake caliper connection
  52
• 3.1 Work instructions
  52
• 4 Overview of electromechanical parking brake components
  57
• 4.1 Removing and installing control unit for electromechanical parking brake J540
  58
• 4.2 Removing and installing parking brake motor
  58
• 5 Assembly overview - brake pedal
  61
• 5.1 Separating brake pedal from brake servo
  62
• 5.2 Removing and installing brake pedal
  63
• 5.3 Adjusting brake pedal position sender G100 , LHD vehicles
  64
• 5.4 Adjusting brake pedal position sender G100 , RHD vehicles
  66
• Brakes - hydraulics
  69
• 1 Repairing front brake calipers
  69
• 1.1 Assembly overview - brake caliper, Brembo 17"
  69
• 1.2 Assembly overview - brake caliper, Brembo 18"
  69
• 1.3 Removing and installing piston for 17" and 18" Brembo caliper
  70
• 2 Repairing rear brake calipers
  73
• 2.1 Assembly overview - brake caliper, Brembo 17"
  73
• 2.2 Removing and installing rear brake caliper piston
  73
• 3 Pressurised leak test
  76
• 4 Bleeding brake system
  77
• 4.1 Bleeding brake system with brake filling and bleeding equipment VAS 5234
  77
• 4.2 Changing brake fluid
  79
• 5 Assembly overview - brake servo/brake master cylinder
  80
• 5.1 Removing and installing brake light switch F , left-hand drive
  81
• 5.2 Removing and installing brake light switch F , right-hand drive
  82
• 6 Brake servo vacuum supply
  84
• 6.1 Overview - vacuum pump for brake servo (diesel vehicles)
  84
• 6.2 Assembly overview - vacuum pump for brakes V192
  84
• 6.3 Removing and installing vacuum line with vacuum sender G608 , right-hand drive model
  87
• 6.4 Checking brake servo vacuum system
  88
• 6.5 Checking non-return valve
  92
• 7 Removing and installing brake master cylinder
  93
• 7.1 Removing and installing brake master cylinder, left-hand drive
  93
• 7.2 Removing and installing brake master cylinder, right-hand drive vehicle
  94
• 8 Removing and installing brake servo
  98
• 8.1 Removing and installing brake servo, left-hand drive
  98
• 8.2 Removing and installing brake servo, right-hand drive vehicle
  99
• 9 Repairing brake lines
  104
• 9.1 Assembly overview - flanging tool
  104
• 9.2 Work instructions
  105