Remove/install brake booster

AR43.10-S-0350EA

Remove/install brake booster

06.03.2020

Model

447 with engine 654.9

Shown on model 447 with code HH9 (TEMPMATIC semi-automatic controlled air conditioning)

1

Brake booster

Shown on model 447 with code HH9 (TEMPMATIC semi-automatic controlled air conditioning)

1

Brake booster

7.2

Refrigerant line

2

Brake lines

8

Screw

3

Nuts

9

Refrigerant line

4

Nut

10

Vacuum line

5

Bracket

11

Bracket

6

Nut

11.1

Retaining tab

7.1

Refrigerant line

12

Elastomer strips

13

Cotter pin

15

Nuts

14

Thrust rod

 Danger

Risk of fire due to ignition of R1234yf refrigerant on hot components. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with escaped R1234yf refrigerant and when working on pressurized parts. Risk of explosion due to formation of ignitable refrigerant/air mixtures

Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated rooms. Carry out repair work on the air conditioning system circuit only after the system has been evacuated.

AS83.00-Z-0007-01A

 Warning

Risk of poisoning caused by inhaling overheated refrigerant vapors from an air conditioning system containing R134a. Risk of injury to skin and eyes caused by contact with liquid R134a refrigerant and when working on pressurized parts

Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated rooms. Carry out repair work on the air conditioning system circuit only after the system has been evacuated.

AS83.00-Z-0006-01A

 Caution

Risk of poisoning from swallowing brake fluid. Risk of injury from skin and eye contact with brake fluid

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

AS42.50-Z-0001-01A

Topical note

Protect air conditioning circuit and components from moisture when carrying out repair work

AH83.30-N-0005-01A

Topical note

Brake fluid notes

AH42.50-P-0001-01A

Notes on handling refrigerant R1234yf

AH83.30-P-0003-02A

Notes on handling refrigerant R134a

AH83.30-N-0003-01A

 

Remove/install

1

Reduce vacuum in brake booster (1) by depressing the brake pedal several times.

2

Discharge air conditioning system.

Model 447 with code HX1 (R-1234yf refrigerant)

AR83.30-S-1760EF

Model 447 except code HX1 (R-1234yf refrigerant)

AR83.30-S-1760E

3

Clean area surrounding cap on brake fluid reservoir and connections of brake lines (2) on master brake cylinder and on hydraulic unit.


Before opening the brake system, it must be ensured that the area around the connecting points has been cleaned completely.
Otherwise minute dirt particles can get into the hydraulic components and result in malfunctions or total failure of the brake system.

 Use clean, lint-free rag only.

 Do not use any compressed air for cleaning when the brake system is open.

Assembly cleaner

*BR00.45-Z-1028-04A

4

Remove cap from brake fluid reservoir and take sieve out of brake fluid reservoir.

5

Extract brake fluid from brake fluid reservoir, insert sieve and then reseal brake fluid reservoir.

6

Remove air/water duct.

AR83.25-S-1410E

7

Remove air filter housing.

AR09.10-S-1150EA

8

Remove brake lines (2) and seal openings using suitable stop plugs.

 Retaining screw, brake line to hydraulic unit

*BA42.10-N-1003-04D

 Retaining screw, brake line to master brake cylinder

*BA42.10-N-1004-04D

 Box wrench bit

*000589750300

 Record plug

*129589009100

9

Remove nuts (3).

MODEL 447 with CODE HH4 (THERMOTRONIC automatic air conditioning) or CODE HH9 (Semi-automatically controlled air conditioning, TEMPMATIC)

10

Unscrew nut (4) and remove holder (5).

MODEL 447 with CODE HH4 (THERMOTRONIC automatic air conditioning) or CODE HH9 (Semi-automatically controlled air conditioning, TEMPMATIC)

11

Remove nut (6), detach refrigerant lines (7.1, 7.2) from expansion valve and seal openings using suitable stop plugs.

MODEL 447 with CODE HH4 (THERMOTRONIC automatic air conditioning) or CODE HH9 (Semi-automatically controlled air conditioning, TEMPMATIC)



Compressor oils (specification 362.1)

BB00.40-P-0362-01A

 Installation: Replace sealing rings and moisten with compressor oil.

 Nut, refrigerant line to expansion valve

*BA83.30-N-1001-01A

 Record plug

*129589009100

12

Unscrew screw (8), detach refrigerant line (9) and seal openings using suitable stop plugs.

MODEL 447 with CODE HH4 (THERMOTRONIC automatic air conditioning) or CODE HH9 (Semi-automatically controlled air conditioning, TEMPMATIC)



Compressor oils (specification 362.1)

BB00.40-P-0362-01A

 Installation: Replace sealing ring and moisten with compressor oil.

 Threaded connection, refrigerant line to refrigerant line

*BA83.30-N-1017-01A

 Record plug

*129589009100

13

Remove holders of refrigerant line (7.1) from driver's side longitudinal member.

MODEL 447 with CODE HH4 (THERMOTRONIC automatic air conditioning) or CODE HH9 (Semi-automatically controlled air conditioning, TEMPMATIC)

14

Detach vacuum line (10) from brake booster (1).

 Installation: Check seal for vacuum line (10) in brake booster (1) for damage and leak tightness.

If the seal is damaged or no longer seals correctly



install new gasket.

15

Remove steering column tube.

AR46.10-S-0400E

16

Remove cotter pin (13) and detach push rod (14) from brake pedal.

17

Remove nuts (15).

 Nut, brake booster to firewall

*BA43.10-N-1001-01C

18

Bend open retaining tabs (11.1) of holders (11) in direction of arrow (arrow A) and open holders (11) in direction of arrow (arrow B).

MODEL 447 with CODE HH4 (THERMOTRONIC automatic air conditioning) or CODE HH9 (Semi-automatically controlled air conditioning, TEMPMATIC)

19

Release refrigerant lines (7.1, 7.2) from holders (11).

MODEL 447 with CODE HH4 (THERMOTRONIC automatic air conditioning) or CODE HH9 (Semi-automatically controlled air conditioning, TEMPMATIC)

 Installation: Observe correct position of elastomer strips (12).

20.1

Remove brake booster (1) forwards.

Model 447 without code HH4 (THERMOTRONIC automatic climate control) or model 447 without code HH9 (Semi-automatically controlled air conditioning, TEMPMATIC)

 Installation: Replace seal between brake booster (1) and firewall.

20.2

Guide out brake booster (1) under refrigerant lines (7.1, 7.2) and remove forwards.

MODEL 447 with CODE HH4 (THERMOTRONIC automatic air conditioning) or CODE HH9 (Semi-automatically controlled air conditioning, TEMPMATIC)

 Installation: Replace seal between brake booster (1) and firewall.

 WIS Service Media
wsm://04_201900_93

21

Remove master brake cylinder.

If the brake booster (1) is to be replaced.

AR42.10-S-0300E

22

Install in the reverse order.

23

Bleed brake system.

AR42.10-S-0010E



Check

24

Perform brake test.



AP42.00-S-4290E

 Brake lines, brake hoses

Number

Designation

Model 447, 448

BA42.10-N-1003-04D

Retaining screw, brake line to hydraulic unit

Nm

14

 Brake lines, brake hoses

Number

Designation

Model 447, 448

BA42.10-N-1004-04D

Retaining screw, brake line to master brake cylinder

Nm

14

 Brake booster

Number

Designation

Model 447, 448

BA43.10-N-1001-01C

Nut, brake booster to firewall

Nm

20

 Air conditioning

Number

Designation

Model 447 with engine 654

BA83.30-N-1001-01A

Nut, refrigerant line to expansion valve

Nm

14

 Air conditioning

Number

Designation

Model 447 with engine 654

BA83.30-N-1017-01A

Threaded connection, refrigerant line to refrigerant line

Nm

20

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01