Removing and installing brake booster - AR43.10-P-0350-01A

BRAKE BOOSTER-PNEUMATIC

Number	Designation		Model 208
BA43.10-P-1002-01A	Nut of brake booster carrier on front end	Nm	20

Unscrew fixing (1) of fuel pipes
Pull off rubber seal (2).
Remove clips (4) and unscrew nut (5), loosen sound insulation mat (3) on firewall and push away on the engine side.

Fig 1: Identifying Fixing, Rubber Seal, Sound Insulation Mat, Clips & Nut
Unscrew bolts (arrows) on firewall.

Fig 2: Identifying Bolts On Firewall
Blank off vacuum line (6) on brake booster (16).
Disconnect plug (S11.1) on brake fluid level sensor.
On vehicles with BAS without ESP: Disconnect plugs (arrows) on BAS control module (N48) and remove BAS control module (N48).
On vehicles with ESP: Disconnect plug on diaphragm travel sensor and BAS solenoid valve release switch on brake booster.

On vehicles with BAS and ESP the BAS control module is integrated in the ESP control module.

Fig 3: Identifying BAS Control Module, Vacuum Line, Brake Booster & Plug
Unscrew windshield washer fluid reservoir (7) and tilt to one side.
Draw off brake fluid from reservoir.
Remove brake pipes (8, 9).
Remove any brake fluid which drips in the vehicle immediately.

Fig 4: Identifying Brake Pipes & Fluid Reservoir
Open fuse box (F), unscrew upper section of fuse box and unhook electric cables (10, 11) from duct.

Fig 5: Identifying Fuse Box & Electric Cables
Pull off locking device (27) and pull out pin (26).
Unscrew nuts (23) from brake booster .
Remove brake booster (16).
Do not damage cup seal (arrow)
Check sealing washers (21) between firewall and brake booster (16) for damage and correct seat and, if necessary, replace.
Install in reverse order

Fig 6: Identifying Brake Booster Components