Remove/install brake booster

AR43.10-P-0350I

Remove/install brake booster

2.6.97

11.3.04

Repair method revised as per economics based on time requirement

 

Remove/Install

 Danger!

Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake fluid coming into contact with skin and eyes.

Pour brake fluid only into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.

AS42.50-Z-0001-01A



Notes on handling brake fluid

AH42.50-P-0001-01A



Notes on repairs to brake system

AH42.00-P-0003-01A



Notes on externally invisible brake fluid loss

AH42.10-P-9406-02A



In order to prevent paint damage, brake fluid which has escaped must be rinsed off immediately with water

1

Open engine hood

AR88.40-P-1000M

2

Remove master brake cylinder (1).

 Check brake master cylinder for leaks at rear of thrust rod piston.

AR42.10-P-0300I

3

Remove gasket (33)

4

Detach cover (34) of cable duct

5

Remove brake lines (31)

6

Remove left wiper arm

AR82.30-P-6100M

7

Loosen cover (32) on the left side and pull forwards slightly

8

Remove left cover below instrument panel

Model 215

AR68.10-P-1500N

Model 220

AR68.10-P-1500M

9

Remove stop lamp switch (S9/1)

AR42.10-P-0040I

10

Detach cover (22) of pedal assembly

11

Pull off retainer (25) at brake booster to brake pedal and remove bolt (26)

12

Detach connector from BAS release switch (A7/7s1)

13

Detach connector from diaphragm travel sensor (A7/7b1)

14

Disconnect vacuum line (8) from brake booster (16)

 Check gasket, replace if necessary.

15

Unscrew mounting nuts (23, 2 pieces) of brake booster



*BA43.10-P-1002-01A

16

Lift up cover (32) and remove brake booster (16)

 Do not damage front timing case and rubber sleeve when removing and installing brake booster.

17

Install in the reverse order

18

Bleed brake system

AR42.10-P-0010I

19

Adjust stop lamp switch (S9/1)

 Refer to: 

Remove/install stop lamp switch

AR42.10-P-0040I



Check

20

Check brake system for leaks

AR42.10-P-0100-01A

Number

Designation

Model 215

Model 220

BA43.10-P-1002-01A

Nut, brake booster carrier to front end

Nm

24

24