Brake systems as of January 1996

Chapter overview

• Technical data
  1
• 1 Brake allocation via PR No
  1
• 1.1 Front brakes
  2
• 1.2 Rear brakes
  5
• 2 Brake test
  7
• 2.1 General
  7
• 2.2 Test for vehicles with front-wheel drive
  7
• 2.3 Test for vehicles with four-wheel drive via a viscous clutch
  7
• Anti-lock brake system
  9
• 1 General notes for anti-lock brake system (ABS)
  9
• 1.1 ABS and ABS/EDL Bosch 5
  9
• 1.2 ABS and ABS/EDL Bosch 5.3
  9
• 1.3 ABS/EDL/TCS/ESP Bosch 5.3
  10
• 2 Notes for repair work on ABS
  12
• 3 Assembly overview - hydraulic units
  13
• 3.1 ABS and ABS/EDL Bosch 5
  13
• 3.2 ABS and ABS/EDL Bosch 5.3
  15
• 3.3 ABS/EDL/TCS/ESP Bosch 5.3
  18
• 4 Removing and installing parts of ABS system on front and rear axle
  23
• 4.1 Removing and installing parts of ABS system on front axle
  23
• 4.2 Removing and installing parts of ABS system on rear axle
  24
• 5 Removing and installing parts of ESP system
  27
• 5.2 Removing and installing control unit J104
  28
• 5.3 Removing and installing steering angle sender G85
  28
• Brakes - mechanism
  30
• 1 Repairing front brakes
  30
• 1.1 Front brake caliper distinguishing features
  30
• 1.2 Repairing front brakes, 15" running gear, floating caliper brake Lucas C54
  31
• 1.3 Removing and installing brake pads, 15" running gear, floating caliper brake Lucas C54
  32
• 1.6 Repairing front brakes, 15" running gear, floating caliper brake FN 3
  36
• 1.7 Removing and installing brake pads, 15" running gear, floating caliper brake FN 3
  38
• 1.8 Repairing front brakes, 16" running gear, floating caliper brake FN 3
  40
• 1.9 Removing and installing brake pads, 16" running gear, floating caliper brake FN 3
  42
• 1.10 Repairing front brakes, 16" running gear, floating caliper brake FNR
  44
• 1.11 Removing and installing brake pads, 16" running gear, floating caliper brake FNR
  46
• 2 Repairing rear brakes
  48
• 2.1 Repairing rear brakes, 15" running gear
  48
• 2.2 Removing and installing brake pads, 15" running gear
  50
• 2.3 Repairing rear brakes, 16" running gear
  52
• 2.4 Removing and installing brake pads, 16" running gear
  54
• 3 Repairing handbrake
  58
• 3.1 Removing and installing handbrake lever
  58
• 3.2 Removing and installing front handbrake cable
  59
• 3.3 Removing and installing pull rod
  60
• 3.4 Removing and installing rear handbrake cable
  61
• 3.5 Adjusting handbrake
  63
• 4 Assembly overview - brake pedal
  64
• 4.1 Removing and installing brake pedal
  65
• Brakes - hydraulics
  66
• 1 Repairing front brake calipers
  66
• 1.1 Repairing front brake calipers, 15" running gear, floating caliper brake Lucas C54
  66
• 1.3 Repairing front brake calipers, 15" running gear, floating frame caliper brake Lucas RC 54
  68
• 1.5 Repairing front brake calipers, 15" running gear, floating caliper brake FN 3
  71
• 1.7 Repairing front brake calipers, 16" running gear, floating caliper brake FN 3
  74
• 2 Repairing rear brake caliper
  81
• 2.1 Removing and installing piston for rear brake caliper
  82
• 2.2 Pressure leak test
  84
• 3 Bleeding brake system
  85
• 3.1 Bleeding brake system with brake filling and bleeding unit V.A.G 1869
  85
• 3.2 Bleeding brake system without brake filling and bleeding unit
  86
• 4 Assembly overview - brake pressure regulator
  88
• 4.1 Adjusting the brake pressure regulator
  89
• 5 Assembly overview - brake servo/brake master cylinder
  94
• 5.1 Checking non-return valve
  95
• 5.2 Removing and installing brake master cylinder
  95
• 5.3 Removing and installing brake servo
  96