Brake systems

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety precautions when working in vicinity of high-voltage components
  1
• 1.2 Safety precautions when working on high-voltage system
  1
• 1.3 Safety measures when working on vehicles with a start/stop system
  2
• 1.5 Safety precautions when tow-starting or towing
  2
• 2 Identification
  3
• 2.1 Allocation of PR number - brakes
  3
• 3 Repair notes
  4
• 3.1 Rules for cleanliness
  4
• 3.2 General information
  5
• 3.3 General repair instructions
  5
• 3.4 Contact corrosion
  5
• 3.5 Gaskets and seals
  5
• 3.6 Nuts and bolts
  6
• 3.7 Routing and attachment of lines
  6
• 3.8 Checking vacuum system
  6
• 4 Technical data
  8
• 4.1 Technical data for brakes
  8
• 5 Brake test
  13
• 5.1 General information
  13
• 5.2 Checking vehicles with front-wheel drive
  13
• 5.3 Checking vehicles with all-wheel drive
  13
• 5.4 Checking parking brake
  14
• 5.5 Checking vehicles with rear-wheel drive
  14
• 6 Classification of dangers of the high-voltage system
  15
• Anti-lock brake system
  16
• 1 General information
  16
• 1.1 Repair instructions for repair work on ABS
  16
• 2 Overview of fitting locations
  19
• 2.1 Overview of fitting locations – ABS/ESP
  19
• 3 Control unit and hydraulic unit
  21
• 3.1 Assembly overview - control unit and hydraulic unit
  21
• 3.2 Removing and installing ABS control unit J104 and ABS hydraulic unit N55
  22
• 3.3 Removing control unit without hydraulic unit
  29
• 3.4 Connecting brake lines to hydraulic unit
  33
• 4 Sensors
  36
• 4.1 Assembly overview - speed sensor on front axle
  36
• 4.2 Assembly overview – speed sensors on rear axle
  37
• 4.3 Removing and installing brake light switch
  39
• 4.4 Removing and installing speed sensors on front axle G45/G47
  40
• 4.5 Removing and installing speed sensors on rear axle G44/G46
  41
• Brakes - mechanism
  43
• 1 Front brake
  43
• 1.1 Assembly overview - front brake
  43
• 1.2 Removing and installing brake pads
  45
• 1.3 Removing and installing brake caliper
  47
• 1.4 Removing and installing brake carrier
  49
• 1.5 Removing and installing brake disc
  50
• 2 Rear brake
  53
• 2.1 Assembly overview - rear brakes
  53
• 2.2 Removing and installing brake pads
  57
• 2.3 Removing and installing brake caliper
  63
• 2.4 Removing and installing brake carrier
  69
• 2.5 Removing and installing brake disc
  71
• 2.6 Removing and installing brake shoes
  74
• 2.7 Resetting drum brakes
  77
• 3 Parking brake
  78
• 3.1 Assembly overview - parking brake
  78
• 3.2 Removing and installing handbrake lever
  84
• 3.3 Adjusting parking brake
  85
• 3.4 Removing and installing front brake cable
  89
• 3.5 Removing and installing rear brake cable
  93
• 4 Brake pedal
  100
• 4.1 Assembly overview - brake pedal
  100
• 4.2 Removing and installing mounting bracket
  101
• 4.3 Separating brake pedal from brake servo
  104
• 4.4 Connecting brake pedal to brake servo
  105
• 4.5 Removing and installing brake pedal
  106
• Brakes - hydraulics
  107
• 1 Front brake caliper
  107
• 1.1 Assembly overview – front brake caliper
  107
• 1.2 Removing and installing brake caliper piston
  107
• 2 Rear brake caliper
  111
• 2.1 Assembly overview – rear brake caliper
  111
• 2.2 Removing and installing brake caliper piston
  112
• 3 Brake servo and brake master cylinder
  119
• 3.1 Assembly overview - brake servo/brake master cylinder
  119
• 3.2 Removing and installing brake servo
  120
• 3.3 Removing and installing brake master cylinder
  122
• 3.4 Removing and installing brake fluid reservoir
  125
• 4 Vacuum system
  128
• 4.1 Assembly overview - electric vacuum pump
  128
• 4.2 Assembly overview - vacuum pump
  128
• 4.3 Checking non-return valve
  129
• 4.4 Removing and installing non-return valve
  129
• 4.5 Removing and installing vacuum sender G608
  130
• 4.6 Checking vacuum system
  130
• 4.7 Removing and installing vacuum pump
  135
• 5 Brake lines
  138
• 5.1 Repairing brake lines
  138
• 6 Hydraulic system
  144
• 6.1 General notes on brake fluid
  144
• 6.2 Pre-bleeding hydraulic system
  145
• 6.3 Bleeding hydraulic system following standard procedure
  146
• 6.4 Subsequent bleeding of hydraulic system
  147
• 6.5 Testing for leaks
  147