The brake system consists of a master brake cylinder, a vacuum brake booster and wheel disc brakes (see illustrations 1.0 and 1.0a).
The brake hydraulic system is divided into two circuits, functioning diagonally.
One hydraulic circuit acts on the front right and rear left wheels, and the other - on the front left and rear right. This makes it possible to stop the vehicle with sufficient efficiency in the event of, for example, a leak in one of the circuits of the brake system.
The pressure for both circuits is created by double (tandem) master brake cylinder when applied to the brake pedal.
The expansion tank with brake fluid is located in the engine compartment above the master brake cylinder.
From it, the brake fluid provides the entire brake system, as well as the hydraulic clutch.
The engine brake vacuum booster uses the vacuum in the intake manifold and increases the applied force when the brake pedal is depressed.
Some models with a gasoline engine and an automatic transmission are equipped with an electrically driven vacuum pump. In this case, the vacuum pump is attached to the front of the automatic transmission.
Due to the fact that a diesel engine has almost no vacuum in the intake manifold, vehicles with a diesel engine are equipped with a special brake booster vacuum pump. The vacuum pump is mounted on the cylinder head along with the fuel pump and is driven by the camshaft.
Brake linings are a category of materials that require a license to operate and are listed in the General Operating Permit (AVE).
In addition, they are selected by the manufacturer for certain car models. Therefore, it is recommended to use only pads offered by the manufacturer or approved by the Federal Automobile Administration.
These pads have a number assigned to them by the Federal Automobile Administration.
Attention! When driving on wet roads, it is recommended to brake from time to time to clean the brake discs. Although water is shed off the brake discs by centrifugal forces, a thin layer of silicones, rubber wear products, grease and other contaminants are still left on them, which impair brake response.
Burnt dirt on the brake linings and clogged water drainage slots in the brake linings lead to serrated brake discs. Because of this, the effect of the brakes may deteriorate.
Attention! When cleaning the brake system, dust is generated. This dust is harmful to human health. Therefore, when cleaning the brake system, use a respirator to prevent brake dust from entering the respiratory tract.
ABS/HBA/EBV/EDS/ASR/ESP
Self-repair of electronic components of the brake system is not allowed. Have these components repaired by a specialist workshop.
Anti-lock braking system (ABS) prevents blocking of wheels at sharp braking. Thanks to this, the car remains steerable even when braking to a complete stop.
Hydraulic brake booster (NVA)
By how hard the brake pedal is applied, the electronic booster determines the occurrence of a dangerous situation. Within milliseconds, it creates the necessary pressure in the brake system and shortens the braking distance, even if the driver does not have time to depress the brake pedal with the force necessary to stop the car.
Electronic brake force distributor (EBV)
brake force distributor (EBV) redistributes braking force between the rear wheels using ABS hydraulics.
When driving in a straight line, the brake mechanisms of the rear wheels in the event of braking are activated with full efficiency.
In order to ensure the stability of the vehicle during cornering braking, it is necessary to reduce the braking effect experienced by the rear wheels. Based on the information transmitted by the ABS sensors about the speed of rotation of the wheels, the electronic distributor recognizes whether the car is moving in a straight line or making a turn.
When cornering, the braking force on the rear wheels is reduced, which provides them with maximum side-slip force, preventing the car from skidding when cornering.
Electronic differential lock (EDS)
By means of an electronic differential lock, a slipping wheel is braked and traction is transferred to the wheel that does not slip, but has a stronger grip on the soil or road surface. EDS turns on immediately at the moment of starting the movement and automatically turns off when the car develops a speed of about 40 kilometers per hour. EDS also functions when reversing.
Anti-slip system (ASR)
The system brakes slipping wheels and transfers torque to those wheels that are firmly traction. The system monitors the rotation of the wheels and brakes them if they start to slip.
The ESP warning light on the instrument panel starts flashing, informing the driver that one of the wheels has reached a point that is regarded as slipping. ASR can be disabled with the ESP switch located on the center console. In this case, the ESP warning light on the instrument panel lights up.
Attention! When driving on sand, gravel or deep snow, it may be necessary to drive with wheel spin and without engine braking. In such cases, ASR can be deactivated by pressing the switch on the center console.
System for automatic stabilization of vehicle stability when making a turn (ESP). ESP combines the functions of EDS and ASR.
When cornering at high speeds or when making sharp manoeuvres, the stability control recognizes «intention» vehicle to lose stability. To this end, the ESP control unit takes into account the information from the sensors about the angle of rotation, and also, based on the speed of the vehicle, calculates the angular velocity (rotational speed) vehicle relative to the vertical axis and instantly determines the moment when the vehicle may lose stability.
By adjusting the pressure in the brake mechanisms of the respective wheels, as well as slowing down the engine, ESP ensures that the car instantly returns to a position in which nothing threatens its stability.
Attention! In order for ESP to function flawlessly, it is necessary that the same tires are installed on all four wheels of the car.
ESP operation is indicated by the warning light on the instrument panel.
The driver in such cases must take into account the traffic situation and change the speed. Otherwise, the car may skid.
The interlock in the ABS / ESP / EDS control unit ensures automatic shutdown of the system in the event of a malfunction, for example, when the power wire is broken or when the battery voltage drops below 10 V.
The deactivation of the corresponding system is signaled by the corresponding control lamp on the instrument panel.
The normal braking system retains its effect when the ABS/ESP/EDS is deactivated. In this case, the vehicle behaves as if it were not equipped with ABS/ESP/EDS systems.
Attention! If, while driving, one or more warning lights on the instrument panel come on, it is recommended to do the following:
- 1. Stop, turn off the engine. and then run it again.
- 2. Check battery voltage. If the battery voltage is less than 10.5 U, then charge the battery.
Attention! If the warning lights come on at the beginning of the movement, and go out after a while, this indicates that the battery voltage was too low, but then increased during the movement as a result of recharging from the generator.
- 3. Check if the wire terminals are securely fastened to the battery terminals.
- 4. Place the vehicle on jack stands and remove the wheels. Check sensor wires for external damage (grinding). Further checking of ABS/ESP/EDS should be carried out in a workshop.
Attention! When working with electric welding, the plug of the ABS electronic control unit must be disconnected. The plug is located in the engine compartment. Disconnect the plug only when the ignition is off. When performing paint work, the control unit can be subjected to short-term exposure to high temperatures not exceeding +95°C and long-term (maximum within 2 hours) temperature not higher than +85°С.
1.0. Front wheel brakes with FS-III caliper. Golf cars with small engines
1 - bolts. Tightening torque 10 Nm
2 - brake disc. When replacing, install new brake discs on both wheels
3 - locking bolt of the brake disc. Tightening torque 4 Nm
4 - brake pads with wear sensor. When replacing pads, it is mandatory to install new pads on both brake mechanisms
5 - brake pad wear sensor with plug
6 - support
7 - guide pin. Tightening torque 30 Nm
8 - guide pin head cover
9 - brake hose with fitting and hollow screw. Tightening torque 35 Nm
10 - guide pin Tightening torque 30 Nm
11 - guide pin head cover
12 - a bolt of fastening of the holder of a brake hose
13 - brake hose holder and brake pad wear sensor wires
14 - steering knuckle with shoe guide
15 - ABS sensor. Before installing the sensor, clean the hole and lubricate it with high temperature grease, such as Liqui Moly ceramic paste
16 - a bolt with a head under a six-sided socket wrench. Tightening torque 8 Nm
17 - hub with bearing and ABS sensor gear
18 - protective cover of the brake mechanism
1.0a. Front wheel brakes with FN-III caliper. Touran and Golf cars with high power engines
1 - brake disc locking bolt. Tightening torque 4 Nm
2 - brake disc. When replacing, install new brake discs on both wheels
3 - brake pads with wear sensor. When replacing pads, it is mandatory to install new pads on both brake mechanisms
4 - spring pads. Installed in two holes on the caliper
5 - brake shoe guide. Attaches to the steering knuckle
6 - support
7 - guide pin. Tightening torque 30 Nm
8 - guide pin head cover
9 - brake hose with fitting and hollow screw. Tightening torque 35 Nm
10 - bolts for fastening the guide pads. Tightening torque 190 Nm
11 - a bolt of fastening of the holder of a brake hose
12 - brake hose holder, brake pad wear sensor wires and ABS sensor wires
13 - steering knuckle
14 - ABS sensor. Before installing the sensor, clean the hole and lubricate it with high temperature grease, such as Liqui Moly ceramic paste
15 - a bolt with a head under a six-sided socket wrench. Tightening torque 8 Nm
16 - protective cover of the brake mechanism
17 - bolts. Tightening torque 10 Nm
18 - hub with bearing and ABS sensor gear
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