Specifications

Dual-circuit hydraulic brake system with vacuum brake booster.

The brake booster incorporates Brake Assist (BAS).

Ventilated discs at the front and solid discs at the rear.

Mechanical parking brake operated by a floor-mounted lever and cables acting on the rear wheels.

Anti-lock braking system (ABS) with electronic stability program (ESP), including traction control (ASR), fitted as standard across the range.

Front brakes

Ventilated disc brakes with single-piston floating calipers.

DISCS

New thickness:

• petrol engine: 22 mm,
• diesel engine: 25 mm.

Wear limit:

• petrol engine: 19.4 mm,
• diesel engine: 22.4 mm.

Wear limit during servicing:

• petrol engine: 20 mm,
• diesel engine: 23 mm.

PADS

New thickness (with backing plate):

• petrol engine: 18.7 mm,
• diesel engine: 19.7 mm.

Wear limit (without backing plate): 2 mm.

Wear limit (with backing plate):

• petrol engine: 11.2 mm,
• diesel engine: 11.7 mm.

Wear limit (without backing plate) during servicing:

• petrol engine: 5 mm,
• diesel engine: 5.5 mm.

Wear limit warning: 3 mm

Rear brakes

Solid disc brakes with single-piston floating calipers, with automatic wear adjustment and integrated parking brake mechanism.

DISCS

New thickness: 8 mm.

Wear limit: 7 mm.

Wear limit during servicing: 7.3 mm.

PADS

New thickness (with backing plate): 14.4 mm.

Wear limit (without backing plate): 2 mm.

Wear limit (with backing plate): 8 mm.

Wear limit (without backing plate) during servicing: 3.5 mm.

Controls

BRAKE BOOSTER

Vacuum brake booster with mechanical brake assist device across the range.

MASTER CYLINDER

Tandem master cylinder.

BRAKE FLUID RESERVOIR

The brake fluid reservoir is mounted above the master cylinder and incorporates a level sensor.

It supplies the hydraulic clutch circuit on vehicles fitted with a manual gearbox.

PARKING BRAKE

Mechanical parking brake operated by cables acting on the rear wheels.

VACUUM PUMP (DIESEL)

Pump mounted on the front housing, driven by the exhaust camshaft, supplying vacuum to the brake booster.

Brake assist management

ABS/ESP/BAS BRAKING SYSTEM

The Bosch ESP stability control is fitted as standard across the entire range. This active safety system improves vehicle stability in all situations. It works by acting individually on the brakes of one or more wheels and/or on engine management. It includes the following functions:

• anti-lock braking system (ABS),
• emergency brake assist (BAS),
• traction control (ASR),
• engine torque control on deceleration (MSR) during heavy downshifts,
• tyre pressure loss detection (RDW) by comparing wheel speeds in a straight line.

ELECTROHYDRAULIC UNIT

It is located near the front left wheel arch, under the brake fluid reservoir (Fig. 1).

Fig. 1

CONTROL UNIT

Digital electronic control unit with 46 pins (numbered 1 to 46) (Fig. 2).

Control unit connector pin assignment (Fig. 2)

Pins	Assignments
1	Ground
2	Power supply via fuse 9
3	Power supply via fuse 15
4	Ground
13	Front left wheel speed sensor signal
15	Rear left wheel speed sensor
16	Rear left wheel speed sensor signal
18	Rear right wheel speed sensor signal
20	Brake light switch
21	Front right brake pad wear switch
25	Low line of the yaw rate and lateral acceleration sensor
28	Power supply after ignition via fuse 25
29	High line of the engine CAN bus
30	Low line of the engine CAN bus
33	Front right brake pad wear switch ground
34	Front left wheel speed sensor
36	Brake fluid level warning switch
38	Rear right wheel speed sensor
39	Front right wheel speed sensor
40	Front right wheel speed sensor signal
41	Parking brake warning switch
44	Vehicle speed output signal
45	Brake light switch
46	High line of the yaw rate and lateral acceleration sensor
Unused pins: 5 to 12, 14, 17, 19, 22 to 24, 26, 27, 31, 32, 35, 37, 42 and 43

Identification of the ABS/ESP control unit connector pins.

YAW RATE AND LATERAL ACCELERATION SENSOR

This sensor is located near the handbrake lever (Fig. 3). It detects the vehicle's rotation speed around its vertical axis and the lateral acceleration.

Location of the yaw rate and lateral acceleration sensor, Fig. 3

The arrow indicates the front of the vehicle

WHEEL SPEED SENSORS

The front wheel speed sensors are mounted on the steering knuckles (Fig. 4), while the rear wheel speed sensors are fixed to the wheel carrier (Fig. 5).

They are powered by the ABS control unit.

Location of the front wheel speed sensor, Fig. 4

Location of the rear wheel speed sensor, Fig. 5

STEERING WHEEL ANGLE SENSOR

The steering wheel angle sensor is mounted on the steering column, behind the steering wheel (Fig. 6). It detects the steering wheel position and sends it to the multiplex network.

Location of the steering wheel angle sensor, Fig. 6

Specifications

BRAKE FLUID

Specification:
Synthetic fluid meeting DOT 4 Plus specifications.

Capacity:
0.6 litre.
Observe the 'MIN' and 'MAX' level marks on the reservoir.

Service interval: Replace and bleed every 2 years.