Remove/install master brake cylinder

AR42.10-P-0300EW

Remove/install master brake cylinder

12.02.2019

Model

207, 212, 218

Modification notes

10.08.2010

Value changed: Nut, support to suspension strut tower

Model 212

BA62.30-P-1006-02G

11.08.2010

"Perform brake test on test bench" reference changed

Test sequence augmented/revised

06.04.2017

Retaining screw, brake line to master brake cylinder

BA42.10-P-1003-04L

1

Water collector

5

Feed hose

9

Vacuum line

2

Strut

6

Screw

10

Brake line

3

Expansion reservoir

7

Master brake cylinder

11

Nut

4

Electrical connector

8

Seal

12

Sealing ring

 

Remove/install

 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

Notes on externally invisible brake fluid loss

AH42.10-P-9406-02A

Topical note

Brake fluid notes

AH42.50-P-0001-01A

Topical note

Notes on repairs to brake system

AH42.00-P-0003-01A

1

Remove vacuum in brake booster

 To do this, press the brake pedal several times with the engine switched off.

2

Open hood

Engine 207, 212

AR88.40-P-1000EW

3

Remove wiper arms

Model 207

AR82.30-P-6100CW

4

Remove air/water duct (1)

Model 207

 Do not disconnect electric feed lines and hoses of spray nozzle.

5

Remove strut (2)

 MODEL 212, 218Nut, strut to suspension strut tower

*BA62.30-P-1006-02G

 Model 207Nut, strut to firewall

*BA62.30-P-1007-02G

 Model 207Screw/bolt, suspension strut to body

*BA32.25-P-1003-04M



Clean

6

Clean area around cap of expansion reservoir (3) and remove cap

7

Drain brake fluid from expansion reservoir (3)

 To prevent paint damage, any escaped brake fluid must be rinsed immediately with water.

8

Release and disconnect electrical connection (4)

9

Detach feed hose (5)

Vehicles with manual transmission

AR25.20-P-0100-01V

 Seal feed hose (5).

 Record plug

*129589009100

10

Remove screw/bolt (6)

11

Detach expansion reservoir (3) from master brake cylinder (7)


Seal connections on master brake cylinder (7)
in order to prevent the ingress of foreign objects.

 Installation: Install new seals (8).

 Record plug

*129589009100

12

Pull vacuum line (9) with check valve out of brake booster

13

Detach brake lines (10) from master brake cylinder (7)

 Seal line connections.

 Retaining screw, brake line to master brake cylinder

*BA42.10-P-1003-04L

 Box wrench bit

*000589750300

 Record plug

*129589009100

14

Unscrew nuts (11)

 Nut, master brake cylinder to brake booster

*BA42.10-P-1001-05K

15

Remove master brake cylinder (7)


Do not tilt master brake cylinder (7), instead pull straight forward out of brake booster.
Otherwise the push rod will be pressed out of its axial position.

 Installation: Replace sealing ring (12).

16

Install in the reverse order

17

Bleed brake system

AR42.10-P-0010EW



Check

18

Check brake system for leaks

AR42.10-P-0100-01V

19

Carry out brake test on the test stand



AP42.00-P-4290BA

 Suspension struts

Number

Designation

Model 207
except code 483 (ADVANCED AGILITY package)

BA32.25-P-1003-04M

Screw/bolt, suspension strut to body

Nm

33

 Master brake cylinder

Number

Designation

Model 207

Model 212

BA42.10-P-1001-05K

Nut, master brake cylinder to brake booster

Nm

25

25

 Master brake cylinder

Number

Designation

Model 218

BA42.10-P-1001-05K

Nut, master brake cylinder to brake booster

Nm

25

 Brake lines, brake hoses

Number

Designation

Model 207

Model 212 (except 212.076/092/276/292)

BA42.10-P-1003-04L

Retaining screw, brake line to master brake cylinder

Ø4.75

Nm

16

16

Ø6

Nm

16

16

Ø8

Nm

16

16

 Brake lines, brake hoses

Number

Designation

Model 212.076/092/276/292

Model 218 (except 218.376/392/976/992)

BA42.10-P-1003-04L

Retaining screw, brake line to master brake cylinder

Ø4.75

Nm

16

16

Ø6

Nm

16

16

Ø8

Nm

16

16

 Brake lines, brake hoses

Number

Designation

Model 218.376/392/976/992

BA42.10-P-1003-04L

Retaining screw, brake line to master brake cylinder

Ø4.75

Nm

16

Ø6

Nm

16

Ø8

Nm

16

 Front end with front reinforcement

Number

Designation

Model 212

Model 218

BA62.30-P-1006-02G

Nut, strut to suspension strut tower

Nm

30

30

 Front end with front reinforcement

Number

Designation

Model 207.3

Model 207.4

BA62.30-P-1007-02G

Nut, strut to firewall

Nm

35

35