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
  4
• 2.1 Brake master cylinder and brake servo
  4
• 2.2 Front brakes
  4
• 2.3 Rear brakes
  5
• 3 Brake test
  7
• 3.1 General
  7
• 3.2 Test for vehicles with front-wheel drive
  7
• Anti-lock brake system
  8
• 1 General notes for anti-lock brake system (ABS)
  8
• 1.1 ABS Mark 60
  8
• 1.2 ABS Bosch 5.7
  9
• 1.3 Bosch 8.0 as of model year 2005
  10
• 2 Notes for repair work on anti-locking brake system
  12
• 3 Connecting VAS 5051 and selecting functions
  13
• 4 Electrical/electronic components and fitting locations
  15
• 4.1 ABS Mark 60 (ABS, ABS/EDL/TCS)
  15
• 4.2 ABS Bosch 5.7 (ABS/EDL/TCS/ESP)
  16
• 4.3 ABS Mark 8.0 (ABS, ABS/TCS)
  18
• 4.4 ABS Bosch 8.0 (ABS/EDL/TCS/ESP)
  19
• 5 Fault display via warning lamps
  21
• 6 Assembly overview - hydraulic unit, brake servo/brake master cylinder
  23
• 6.1 ABS Mark 60
  23
• 6.2 ABS/EDL/TCS/ESP Bosch 5.7
  33
• 6.3 Bosch 8.0 ABS, ABS/TCS
  42
• 6.4 Bosch 8.0 ABS/EDL/TCS/ESP
  50
• 7 Removing and installing parts of ABS system on front and rear axle
  58
• 7.1 Removing and installing parts of ABS system on front axle
  58
• 8 Removing and installing parts of ESP system
  72
• 8.2 Removing and installing steering angle sender G85
  73
• Brakes - mechanism
  74
• 1 Repairing front brakes
  74
• 1.1 Repairing front brakes, brake caliper FS II
  74
• 1.2 Removing and installing brake pads, brake caliper FS II
  75
• 1.3 Removing and installing brake caliper FS II
  77
• 1.4 Repairing front brakes, brake caliper FS III
  79
• 1.5 Removing and installing brake pads, brake caliper FS III
  81
• 1.6 Removing and installing brake caliper FS III
  83
• 1.7 Repairing front brakes, brake caliper C 54-II
  85
• 1.8 Removing and installing brake pads, brake caliper C 54-II
  87
• 1.9 Removing and installing brake caliper C 54-II
  89
• 1.10 Repairing front brakes, FN 3 brake caliper
  91
• 1.11 Removing and installing brake pads, brake caliper FN 3
  93
• 1.12 Removing and installing brake caliper FN 3
  96
• 2 Repairing rear brakes (drum brakes)
  98
• 2.1 Removing and installing rear brakes
  98
• 2.2 Resetting brake
  100
• 2.3 Repairing rear brakes
  100
• 2.4 Removing and installing brake shoes
  101
• 3 Repairing rear brakes (disc brakes)
  104
• 3.1 Removing and installing brake pads
  105
• 3.2 Removing and installing brake caliper
  108
• 4 Assembly overview - handbrake lever
  111
• 4.1 Removing and installing handbrake cable (drum brakes)
  111
• 4.2 Adjusting handbrake
  113
• 4.3 Removing and installing handbrake cable (disc brakes)
  113
• 4.4 Adjusting handbrake
  115
• 5 Assembly overview - brake pedal
  117
• 5.1 Separating brake pedal from brake servo
  117
• 5.2 Removing and installing pedal cluster
  119
• 5.3 Removing and installing brake pedal
  119
• 5.4 Removing and installing brake light switch F and brake pedal switch F47
  121
• Brakes - hydraulics
  123
• 1 Repairing front brake calipers
  123
• 1.1 Repairing brake caliper FS II
  123
• 1.2 Removing and installing piston for brake caliper FS II
  123
• 1.3 Repairing FS III brake caliper
  125
• 1.4 Removing and installing piston for FS III brake caliper
  126
• 1.5 Repairing brake caliper C 54-II
  128
• 1.6 Removing and installing piston for brake caliper C 54-II
  129
• 1.7 Repairing brake caliper FN 3
  131
• 1.8 Removing and installing piston for brake caliper FN 3
  132
• 2 Repairing rear brake caliper
  136
• 2.1 Removing and installing piston for rear brake caliper
  137
• 3 Pressure leak test
  139
• 3.1 Test prerequisites:
  139
• 4 Assembly overview - brake pressure regulator
  140
• 5 Checking and adjusting brake pressure regulator
  141
• 5.1 Checking and adjusting pressure
  141
• 6 Bleeding brake system
  143
• 6.2 Changing brake fluid (every 2 years)
  145
• 7 Assembly overview: Brake servo and master brake cylinder
  146
• 7.1 Vacuum pump for brake servo (diesel vehicles) overview
  147
• 7.2 Checking non-return valve:
  149
• 8 Removing and installing brake master cylinder
  150
• 8.1 Removing
  150
• 9 Removing and installing brake servo
  152
• 9.1 Removing
  152
• 9.2 Installing
  154
• 10 Repairing brake lines
  155
• 10.1 Assembly overview - flanging tool
  155
• 10.2 Work instructions
  156