Remove/install brake booster - AR43.10-P-0350GH

MODEL 163.113 /128 /136 /154 /157 /172 /174 /175

Fig 1: Identifying Brake Booster Components - 1st Version

Fig 2: Identifying Brake Booster Components - 2nd Version

Fig 3: Identifying Brake Lines And Plastic Retaining Nut And Clip

	Remove/install
	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
	Brake fluid notes	All models	AH42.50-P-0001-01A
	Notes on externally invisible brake fluid loss	Model 129, 140, 163, 168, 170, 202, 203, 208, 209,210,215,220,414,460, 461.217/219/223/227/229/238/239/249/ 266/267/302/321/322/323/326/327/328/ 329/332/335/336/337/338/341/342/345/ 365/366/367/368/401/402/403/404/405/ 450/451/452/454/455/456/458/459, 463.200 /204 /206 /207 /208 /209 /220 / 221 /224 /225 /227 /228 /230 /231 /232 / 233 /240 /241 /244 /245 /247 /248 /249 / 250 /254 /300 /304 /307 /308 /309 /320 / 321 /322 /323 /324 /325 /327 /328 /330 / 331 /332 /333, 639	AH42.10-P-9406-02A
	Notes on repairs to brake system	All models	AH42.00-P-0003-01A
1	Remove stepped tandem master brake cylinder (1)	Check brake master cylinder for leaks at rear of thrust rod piston. If leaks present, replace brake master cylinder.	AR42.10-P-0310GH
2	Unscrew nuts (4) of position sensor bracket to bulkhead	Pull hose (21)out of bracket and unclip bracket from splash wall. Unplug connector and swivel bracket to the side.
3	Detach BAS diaphragm travel sensor connector (A7/7b1)
4.1	Undo nut (17) on front left engine mount	Model 163.113 /128.	*BA22.10-P-1010-01D
5.1	Raise engine at left side.	Model 163.113 /128.
			*WE58.40-Z-1012-11A
			*WE58.40-Z-1007-11A
6.1	Remove vacuum pump control unit	Model 163.113 up to VIN 093126.	AR43.05-P-1323GH
7.1	Place brake line (18) to the side.	Model 163.113 /128.
8	Unscrew plastic lock nut (19) at splash wall.	Risk of plastic locking clips (20) cracking and fracturing.
9	Disconnect release switch connector (27).
10	Remove cover beneath instrument panel (left)		AR68.10-P-1500GH
11	Pull out retainer (25) and bolt (26).
12	Unscrew nut (23) of brake booster		*BA43.10-P-1002-01A
13	Remove brake booster (16)	When removing the brake booster from the pedal bearing bracket (22), do not damage the timing case.
14	Replace gasket (16d)
15	Install in the reverse order
16	Adjust stop lamp switch (S9)	Adjust, see: ↓ Remove/install mechanical stop lamp switch.	AR42.10-P-0040GH

Engine suspension, engine mounts, engine supports

Number	Designation		Engine 612.963 in model 163.113	Engine 628.963 in model 163
BA22.10-P-1010-01D	Nut, front engine mount to engine support	Nm	65	66

Pneumatic brake booster

Number	Designation		Model 163
BA43.10-P-1002-01A	Nut, brake booster carrier to front end	Nm	25

Workshop equipment

WE58.40-Z-1007-11A	Engine lifting fixture
WE58.40-Z-1012-11A	Load regulator (engine hoist), self-locking