Brake systems

Chapter overview

• Technical data
  1
• 1 \--- Change history ---
  1
• 2 Identification
  2
• 2.1 Brake PR number correspondence
  2
• 3 Technical data
  4
• 3.1 Brake - technical data
  4
• 4 Brake Test
  7
• 4.1 General information
  7
• 4.2 Information about the test
  7
• 5 Safety indications
  8
• 5.1 Safety measures for test drives with testing and measuring equipment
  8
• Anti-lock brake system
  9
• 1 General information
  9
• 1.1 Information on repair works on the ABS
  9
• 2 Assembly location overview
  11
• 2.1 ABS/ESP - assembly location overview
  11
• 3 Hydraulic unit and control unit
  14
• 3.1 Hydraulic unit and control unit - assembly overview
  14
• 3.2 ABS control unit J104 / ABS hydraulic unit N55 - remove and install
  16
• 3.3 Control unit - remove from the hydraulic unit
  22
• 3.4 Control unit - install on the hydraulic unit
  23
• 3.5 Connect brake pipes in the hydraulic unit
  25
• 4 Sensors
  27
• 4.1 Front wheel speed sensor - assembly overview
  27
• 4.2 Rear axle speed sensor - assembly overview
  28
• 4.3 Front wheel speed sensor G45/G47 - remove and install
  29
• 4.4 Rear wheel speed sensor G44/G46 - remove and install
  30
• 4.5 Steering angle sensor G85 - remove and install
  31
• Brakes - mechanism
  32
• 1 Front wheel brake
  32
• 1.1 Front wheel brake - assembly overview
  32
• 1.2 Brake pads - remove and install
  34
• 1.3 Brake caliper - remove and install
  37
• 1.4 Brake disc - remove and install
  42
• 1.5 Brake disk (knocking) - check
  43
• 2 Rear wheel brake
  44
• 2.1 Rear wheel brake - assembly overview
  44
• 2.2 Brake pads - remove and install
  50
• 2.3 Brake caliper - remove and install
  54
• 2.4 Brake shoes - remove and install (1.6 vehicles)
  56
• 2.5 Adjust the drum brake
  65
• 3 Handbrake
  66
• 3.1 Handbrake - assembly overview
  66
• 3.2 Handbrake lever - remove and install
  67
• 3.3 Handbrake cable - remove and install
  69
• 3.4 Handbrake lever adjustment
  70
• 3.5 Rear brake cable - remove and install
  73
• 4 Brake pedal
  80
• 4.1 Brake pedal - assembly overview
  80
• 4.2 Brake pedal - separate
  82
• 4.3 Fasten the brake pedal to the servo brake
  82
• 4.4 Pedal set - remove and install
  83
• 4.5 Brake pedal - remove and install
  85
• Brakes - hydraulics
  87
• 1 Front brake caliper
  87
• 1.1 Front brake caliper - assembly overview
  87
• 1.2 Plunger for front brake caliper - remove and install
  88
• 2 Rear brake caliper
  91
• 2.1 Rear brake caliper - assembly overview
  91
• 2.2 Brake caliper piston - remove and install
  92
• 3 Brake servo and master cylinder
  96
• 3.1 Brake servo and master-cylinder - assembly overview
  96
• 3.2 Brake light switch - remove and install
  98
• 3.3 Brake servo – remove and install
  99
• 3.4 Master cylinder - remove and install
  104
• 4 Brake pipes
  107
• 4.1 Brake pipes - repair
  107
• 5 Vacuum system
  113
• 5.1 Electric vacuum pump - assembly overview
  113
• 5.2 Retention valve - check
  118
• 5.3 Pressure sensor on the suction pipe G608 - remove and install
  119
• 5.4 Vacuum system - check
  120
• 6 Hydraulic system
  127
• 6.1 General notes regarding the brake fluid
  127
• 6.2 Bleed the brake system
  127
• 6.3 Bleed the brake system later
  128
• 6.4 Tightness assessment
  130