Remove/install brake booster

AR43.10-P-0350LF

Remove/install brake booster

06.03.2020

Model

217, 222

Modification notes

07.08.2014

Retaining screw, brake line to hydraulic unit

MODEL 217 except AMG

BA42.10-P-1004-04N

07.08.2014

Retaining screw, brake line to hydraulic unit

MODEL 217 AMG

BA42.10-P-1004-04N

Shown on model 222

1

Left front wheel well strut

2

Nuts

K40/8

Engine fuse and relay module

Shown on model 222

3

Brake fluid expansion reservoir

4

Master brake cylinder

5

Brake lines

S11

Brake fluid level switch

Shown on model 222

6

Guide pin

7

Nuts

 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

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

 

Remove/install

1

Remove left front wheel well strut (1)

AR82.30-P-6400LF

2

Unscrew nuts (2)

3

Remove engine fuse and relay module (K40/8) and place to one side

4

Remove brake vacuum sensor on BAS brake booster

AR43.10-P-0352LF

5

Suction off brake fluid from the brake fluid expansion reservoir (3).



Clean

6

Clean the master brake cylinder (4) in the area of the brake line connections


Before opening the hydraulic system the area around the separation point should be cleaned thoroughly.
Otherwise minute particles of dirt in the hydraulic components can result in malfunctions and total failure of the hydraulic system.

 Only use clean, lint free rags and cleaner free of mineral oil.
Do not use any compressed-air for cleaning when the brake system is open.

Assembly cleaner

*BR00.45-Z-1028-04A

7

Label brake lines (5) according to connections

8

Detach brake lines (5) from master brake cylinder (4)

 Model 217.364/378/382/384/385/482
Model 217.377/379/477/479
Model 222 (except 222.077/177/178/179)
Model 222.077/177/178/179Retaining screw, brake line to master brake cylinder

*BA42.10-P-1003-04N

 Record plug

*129589009100

9

Detach brake lines (5) on traction system hydraulic unit and turn to one side

 Model 217.364/378/382/384/385/482
Model 217.377/379/477/479
Model 222 (except 222.077/177/178/179)
Model 222.077/177/178/179Retaining screw, brake line to hydraulic unit

*BA42.10-P-1004-04N

10

Disconnect electrical connector from brake fluid level switch (S11)

11

Remove left cover below dashboard

Model 217, 222.0/1/9

AR68.10-P-1500LF

12

Remove guide pin (6)

 Guide pin

*BA29.10-P-1002-02I

13

Unscrew nuts (7) of BAS brake booster

 Nut, pedal assembly to firewall

*BA29.10-P-1001-02I

14

Remove BAS brake booster

If the boot of the BAS brake booster is damaged:



Replace brake booster.

If the brake lines (5) are permanently deformed:



Install new brake lines (5).

AR42.10-P-0020B

15

Transfer master brake cylinder (4)

When replacing the BAS brake booster

AR42.10-P-0300LF

16

Install in the reverse order



Check

17

Carry out brake test on the test stand



AP42.00-P-4290BA

 Pedals, bearing bracket

Number

Designation

Model 217

Model 222

BA29.10-P-1001-02I

Nut, pedal assembly to firewall

Nm

22

22

 Pedals, bearing bracket

Number

Designation

Model 217

Model 222

BA29.10-P-1002-02I

Guide pin

Nm

22

22

 Brake lines, brake hoses

Number

Designation

Model 217.364/382/384/385/482

Model 217.377/378/379/477/478/479

BA42.10-P-1003-04N

Retaining screw, brake line to master brake cylinder

Ø4.75

Nm

18

18

Ø6

Nm

16

16

Ø8

Nm

24

24

 Brake lines, brake hoses

Number

Designation

Model 222 (except 222.077/177/178/179/187/188)

Model 222.077/177/178/179/187/188

BA42.10-P-1003-04N

Retaining screw, brake line to master brake cylinder

Ø4.75

Nm

18

18

Ø6

Nm

18

18

Ø8

Nm

24

24

 Brake lines, brake hoses

Number

Designation

Model 217.364/382/384/385/482

Model 217.377/378/379/477/478/479

BA42.10-P-1004-04N

Retaining screw, brake line to hydraulic unit

Ø4.75

Nm

16

16

Ø6

Nm

16

16

Ø8

Nm

-

-

 Brake lines, brake hoses

Number

Designation

Model 222 (except 222.077/177/178/179/187/188)

Model 222.077/177/178/179/187/188

BA42.10-P-1004-04N

Retaining screw, brake line to hydraulic unit

Ø4.75

Nm

18

18

Ø6

Nm

18

18

Ø8

Nm

24

24

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01