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
• 2 Identification
  2
• 2.1 Allocation of PR number - brakes
  2
• 3 Repair notes
  4
• 3.1 General information
  4
• 3.2 Rules for cleanliness
  4
• 3.3 General repair instructions
  5
• 3.4 Checking vacuum system
  5
• 3.5 Gaskets and seals
  5
• 3.6 Nuts and bolts
  6
• 3.7 Routing and attachment of lines
  6
• 3.8 Contact corrosion
  6
• 4 Technical data
  8
• 4.1 Technical data for brakes
  8
• 5 Brake test
  11
• 5.1 General information
  11
• 5.2 Checking vehicles with front-wheel drive
  11
• 5.3 Checking vehicles with all-wheel drive
  11
• 5.4 Checking parking brake
  12
• 6 Hazard classification of high-voltage system
  13
• Anti-lock brake system
  14
• 1 General information
  14
• 1.1 Repair instructions for repair work on ABS
  14
• 2 Overview of fitting locations
  16
• 2.1 Overview of fitting locations – ABS/ESP
  16
• 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
  19
• 3.3 Separating control unit from hydraulic unit
  24
• 3.4 Fitting control unit to hydraulic unit
  25
• 3.5 Connecting brake lines to hydraulic unit
  27
• 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 speed sensors on front axle G45/G47
  30
• 4.4 Removing and installing speed sensors on rear axle G44/G46
  31
• Brakes - mechanism
  33
• 1 Front brake
  33
• 1.1 Assembly overview - front brake
  33
• 1.2 Removing and installing brake pads
  37
• 1.3 Removing and installing brake caliper
  42
• 1.4 Removing and installing brake carrier
  45
• 1.5 Removing and installing brake disc
  45
• 2 Rear brake
  48
• 2.1 Assembly overview - rear brakes
  48
• 2.2 Removing and installing brake pads
  50
• 2.3 Removing and installing brake caliper
  52
• 2.4 Removing and installing brake carrier
  55
• 2.5 Removing and installing brake disc
  55
• 3 Parking brake
  57
• 3.1 Assembly overview - parking brake
  57
• 3.2 Adjusting parking brake
  58
• 3.3 Removing and installing front brake cable
  58
• 3.4 Removing and installing rear brake cable
  62
• 3.5 Removing and installing handbrake lever
  66
• 4 Brake pedal
  67
• 4.1 Assembly overview - brake pedal
  67
• 4.2 Separating brake pedal from brake servo
  67
• 4.3 Connecting brake pedal to brake servo
  69
• 4.4 Removing and installing brake pedal
  69
• Brakes - hydraulics
  70
• 1 Front brake caliper
  70
• 1.1 Assembly overview – front brake caliper
  70
• 1.2 Removing and installing brake caliper piston
  71
• 2 Rear brake caliper
  78
• 2.1 Assembly overview – rear brake caliper
  78
• 2.2 Removing and installing brake caliper piston
  78
• 3 Brake servo and brake master cylinder
  82
• 3.1 Assembly overview - brake servo/brake master cylinder
  82
• 3.2 Removing and installing brake servo
  83
• 3.3 Removing and installing brake master cylinder
  86
• 3.4 Removing and installing brake fluid reservoir
  89
• 3.5 Removing and installing brake light switch F
  91
• 3.6 Removing and installing brake fluid level warning contact F34
  92
• 4 Vacuum system
  93
• 4.1 Assembly overview - vacuum pump
  93
• 4.2 Checking non-return valve
  93
• 4.3 Removing and installing non-return valve
  94
• 4.4 Checking vacuum system
  94
• 5 Brake lines
  99
• 5.1 Repairing brake lines
  99
• 6 Hydraulic system
  105
• 6.1 General notes on brake fluid
  105
• 6.2 Bleeding hydraulic system following standard procedure
  106
• 6.3 Subsequent bleeding of hydraulic system
  107
• 6.4 Testing for leaks
  107