Brake systems

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety measures when working on vehicles with a start/stop system
  1
• 1.3 Safety precautions when working on high-voltage system
  2
• 1.4 Safety precautions when working in vicinity of high-voltage components
  3
• 2 Identification
  4
• 2.1 Allocation of PR number - brakes
  4
• 3 Repair notes
  5
• 3.1 Checking vacuum system
  5
• 4 Hazard classification of high-voltage system
  6
• 5 Technical data
  7
• 5.1 Technical data for brakes
  7
• 6 Brake test
  10
• 6.1 General information
  10
• 6.2 Checking vehicles with front-wheel drive
  10
• 6.3 Checking vehicles with all-wheel drive
  10
• Anti-lock brake system
  12
• 1 General information
  12
• 1.1 Repair instructions for repair work on ABS
  12
• 2 Overview of fitting locations
  15
• 2.1 Overview of fitting locations – ABS/ESP
  15
• 3 Control unit and hydraulic unit
  18
• 3.1 Assembly overview – control unit and hydraulic unit
  18
• 3.2 Removing and installing ABS control unit J104 and ABS hydraulic unit N55
  20
• 3.3 Separating control unit from hydraulic unit
  25
• 3.4 Fitting control unit to hydraulic unit
  26
• 4 Sensors
  29
• 4.1 Assembly overview - speed sensor on front axle
  29
• 4.2 Assembly overview – speed sensors on rear axle
  29
• 4.3 Removing and installing brake light sensor
  30
• 4.4 Removing and installing speed sensors on front axle G45/G47
  32
• 4.5 Removing and installing speed sensors on rear axle G44/G46
  33
• Brakes - mechanism
  34
• 1 Front brake
  34
• 1.1 Assembly overview - front brake
  34
• 1.2 Removing and installing brake pads
  39
• 1.3 Removing and installing brake caliper
  50
• 1.4 Removing and installing brake disc
  61
• 1.5 Removing and installing brake carrier
  63
• 2 Rear brake
  64
• 2.1 Assembly overview - rear brakes
  64
• 2.2 Removing and installing brake pads
  66
• 2.3 Removing and installing brake caliper
  69
• 3 Parking brake
  72
• 3.1 Assembly overview - parking brake
  72
• 3.2 Adjusting parking brake
  73
• 3.3 Removing and installing front brake cable
  73
• 3.4 Removing and installing rear brake cable
  77
• 4 Brake pedal
  82
• 4.1 Assembly overview - brake pedal
  82
• 4.2 Removing and installing brake light switch
  83
• 4.3 Separating brake pedal from brake servo
  83
• 4.4 Connecting brake pedal to brake servo
  84
• 4.5 Removing and installing brake pedal
  85
• Brakes - hydraulics
  87
• 1 Front brake caliper
  87
• 1.1 Assembly overview – front brake caliper
  87
• 1.2 Removing and installing brake caliper piston
  90
• 2 Rear brake caliper
  98
• 2.1 Assembly overview – rear brake caliper
  98
• 2.2 Removing and installing brake caliper piston
  99
• 3 Brake servo and brake master cylinder
  103
• 3.1 Assembly overview - brake servo/brake master cylinder
  103
• 3.2 Removing and installing brake servo
  105
• 3.3 Removing and installing brake master cylinder
  107
• 3.4 Removing and installing brake fluid reservoir
  110
• 4 Vacuum system
  113
• 4.1 Assembly overview - electric vacuum pump
  113
• 4.2 Assembly overview - vacuum pump
  114
• 4.3 Checking non-return valve
  114
• 4.4 Removing and installing non-return valve
  115
• 4.5 Removing and installing brake servo pressure sensor
  116
• 4.6 Checking vacuum system
  117
• 5 Hydraulic system
  122
• 5.1 General notes on brake fluid
  122
• 5.2 Bleeding hydraulic system following standard procedure
  122
• 5.3 Subsequent bleeding of hydraulic system
  123
• 5.4 Testing for leaks
  124