Brake system of the car Mercedes Sprinter I (903)

Brake system — general information
In accordance with the standards for admitting vehicles to operation in any country, each vehicle must be equipped with a parking brake system and a hydraulic service...

Design of the brake system
The front and rear wheels are equipped with disc brakes, which, with a few exceptions, are identical, i.e. they operate on the same principle. All wheels are equipped...

Brake System Maintenance — General Information
The safety of all road users depends on the proper functioning of the brakes. Therefore, it is necessary to regularly check the condition of the braking system. Don't be...

General description of the various components of the braking system
Master brake cylinder . Converts mechanical force on the brake pedal into hydraulic pressure. Also ensures a rapid drop in system pressure when the pedal is released....

Checking the brake fluid level
Figure 9. Brake fluid reservoir The brake fluid reservoir is located in the engine compartment on the left side at the rear of the master brake cylinder (see figure 9)....

Replacing brake fluid
Brake fluid must be replaced at least once a year. For this, it is better to contact a service center. If you are replacing it yourself, please refer to the following...

Checking the brakes
Choose a quiet street or an empty area with a flat, dry surface. Apply the brakes several times with varying force. If the car pulls to the right, the brakes on the left...

Checking the tightness and serviceability of the brake system
Check the entire length of the system pipes under the vehicle - they should not be corroded, kinked or pinched. Wet black dirt at the joints indicates a leak. Brake...

Checking brake pads
When servicing your car yourself, this type of check is most important. It should be carried out regularly. The front brake pads wear out quite quickly, especially on...

Front disc brakes with floating caliper — general information
As already mentioned, the car is equipped with disc brakes with a floating caliper on the front and rear wheels. This type of mechanism consists of a caliper bracket and...

Replacing the front brake pads
Figure 269. Front brake mechanism design: 1 - Brake caliper bracket (bolted to the front axle); 2 - inner shoe with retaining spring; 3 - guide pin, 25 Nm; 4 - plug; 5 -...

Removal and installation the front brake caliper
Figure 278. Installing and removing the brake caliper: 1 — bolt, 10 Nm; 2 — brake pad wear sensor wire; 3 — brake hose, 12–16 Nm; 4 - bolts, 175-205 Nm; 5 - brake...

Front Brake Caliper Repair
As already mentioned, independent repair of the caliper, for example, replacing the sealing ring from the inside or replacing the boot, is not recommended. If you...

Replacing rear brake pads
Figure 279. Removing and installing rear brake pads: 1 - rear axle; 2 - retaining spring; 3 - outer brake shoe; 4 - inner brake shoe; 5 - brake cylinder; 6 — brake pad...

Installing and removing the rear caliper
Figure 284. Removing and installing the rear brake caliper: 1 — brake pad wear sensor wire mounting bolt, 10 Nm; 2 — brake pad wear sensor; 3 — brake hose, 12–16 Nm; 4 -...

Rear Brake Caliper Repair
Caliper repair (replacing the sealing ring on the inside or the mudguard) it is not recommended to do it on your own. If you suspect a faulty caliper, contact a...

Removal and installation the front brake disc
Figure 286. Securing the front hub when unscrewing the brake disc To remove the brake disc, you must first remove the pads as described above. Then unscrew the caliper...

Removal the rear brake disc
Figure 287. Removing the rear brake disc: 1 — bolt, 105–110 N·m; 2 — caliper bracket; 3 - brake disc; 4 — bolt, 20 Nm Figure 287 shows the rear brake disc mount. To...

Installing the rear brake disc
If necessary, brake discs can be ground for subsequent use. The thickness of the front brake discs is the same on all models - 22 mm. The permissible wear is 19 mm. The...

Master Brake Cylinder — General Information
The master cylinder pistons create brake fluid pressure, which is transmitted further through pipes and hoses to the wheel cylinders. The master cylinder may be leaking....

Removal and installation the master brake cylinder
Figure 290. Removing and installing the master brake cylinder: 1 - brake fluid reservoir cap; 2 - brake fluid reservoir; 3 - master brake cylinder; 4 — union nut of the...

Repair of the main brake cylinder
The cylinder cannot be repaired. If it is faulty, it should be replaced. When purchasing a new cylinder, you should always specify the model and year of manufacture of...

Parking brake — general information
The parking brake is a Duo-Servo system. The word "Duo" means that the braking efficiency is the same in both directions of disk rotation, the word "Servo" means that...

Removal and installation parking brake pads
Figure 292. Removing and installing the parking brake pads: 1 - brake shoe; 2 - return spring of the drive lever; 3 - setting gear; 4 - drive lever For the work you will...

Adjusting the parking brake shoes
The parking brake requires adjustment if the brakes do not work when the lever is raised more than 4 clicks. The parking brake shoes must be adjusted as follows: place...

Adjusting the parking brake cables
To perform the work, the vehicle must be lifted. The parking brake cables must be adjusted in the following order: Figure 296. Parking brake equalizer unscrew the four...

Replacing the front parking brake cable
Figure 299. Replacing the front parking brake cable: 1 - front cable; 2 - parking brake lever; 3 - cable routing in the cabin floor; 4 - equalizer; 5 - fixing clamps The...

Replacing the rear parking brake cables
Before performing any operations, the rear of the vehicle must be raised. The work on replacing cables on both sides is carried out in the same way. The rear cables must...

Brake booster — general information
The booster is located on the left side of the engine compartment, behind the master brake cylinder. Additional pressure is created by a membrane which, when braking,...

Removal and installation the brake booster
Figure 300. Brake booster: 1 - vacuum hose; 2 - amplifier; 3 - gasket; 4 — nut, 25–28 N·m; 5 — pusher finger The work on removing the booster is in many ways similar to...

Bleeding brakes
Bleeding the brake hydraulic system is necessary if any of the hoses or pipes in the system have been opened, or if air has entered the system in another way. At the...

Anti-lock braking system (ABS)
Self-repair of ABS is not recommended, with the exception of removing and installing speed sensors. At the front, the sensors are installed in the steering knuckles, and...

Vacuum pump — removal and installation
Figure 302. Fastening the vacuum pump to the front of the engine: 1 - tension roller (if it is installed); 2 - sealing gasket; 3 - vacuum pump; 4 — mounting bolt; 5 -...

Brake system specifications
Front and rear brakes: all models except mod. 412D - Floating caliper with piston 412D - Dual piston floating caliper Area of action on the axis, cm²: front brakes,...

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Vito 1 (1996-2003)