 |
Risk of poisoning
from swallowing brake fluid. Risk of injury
from skin and eye contact with brake fluid. |
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 |
 |
Notes on brake fluid |
All models |
AH42.50-P-0001-01A |
|
Notes if loss of brake fluid is not visible externally |
Models 129, 140, 163, 168, 170, 202, 203, 208, 209, 210, 215, 220, 414, 460, 461, 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 |
AH42.10-P-9406-02A |
|
Notes on repairs to brake system |
Model 163 |
AH42.00-P-0003-01A |
| 1 |
Open engine hood and raise to vertical position |
Model 163.136/154/172 up to VIN A145272, X708318 |
AR88.40-P-1000GH |
| |
|
Model 163.136/154/172 as of VIN A145273, X708319, model 163.113/128/174/175 |
AR88.40-P-1000GI |
| 2.1 |
Remove engine cover |
Model 163.113/128. |
|
| 3 |
Remove fuse and relay module covers |
2 covers. 5 bolts for rear cover. Remove fuse panel. |
|
| 4 |
Unplug connector from reservoir (10) |
|
|
| 5 |
Disconnect vacuum line (8) from brake booster (16) |
|
|
| 6.1 |
Disconnect vacuum line, vehicles with diesel engine (8a) and auxiliary line from splash wall. |
Model 163.113/128. |
|
| 7.1 |
Detach hose (20) from vacuum pump (21) |
If installed. |
|
| 8.1 |
Separate hoses (22) from bracket (23) |
Model 163.113/128. |
|
| 9 |
Detach hoses from the side of the fuse and relay module and place on the engine |
|
|
| 10 |
Unscrew brake lines (5) from tandem master brake cylinder. |
Label brake line in relation to appropriate connection before unscrewing to avoid mixing up brake lines and hoses on vehicles with flexible brake hoses. |
AR42.50-P-0002GH |
| |
|
Seal off connections with plugs. |
|
| |
|
 |
*BA42.10-P-1003-04A |
| |
|
 |
Fig 4 |
| 11.1 |
Unplug ESP brake pressure sensor 1 (B34/1) and ESP brake pressure sensor 2 (B34/2) connectors. |
If installed.
To disconnect, press the release catch on the underside of the plug. |
|
| 12 |
Unscrew nuts (19) of tandem master brake cylinder (1) |
Installation:
Install new self-locking nuts. |
|
| |
|
|
*BA42.10-P-1001-05A |
| 13.1 |
Remove heat shield (1b) |
If installed. |
|
| 14.1 |
Remove anti-theft alarm system siren from splash wall |
If installed. |
|
| 15 |
Remove tandem master brake cylinder (1) |
Do not tilt tandem master brake cylinder but pull it straight out towards the front, otherwise the thrust rod is forced out of its axial position.
Installation:
Replace sealing ring (1a).
Check master brake cylinder for leaks at rear of primary piston. If leaks are found, replace master brake cylinder. |
|
| 16.1 |
Detach clutch operator hose, vehicles with manual transmission (10b) from fluid reservoir and plug fitting. |
Vehicles with manual transmission. |
|
| 17 |
Remove tandem master brake cylinder (1) and place on workbench |
|
|
| 18 |
Suction off brake fluid from brake fluid reservoir (10) |
|
|
| 19 |
Pull the reservoir (10) off the tandem master brake cylinder (1) |
Inspect reservoir plug (9) and install new plug if necessary. |
|
| 20 |
Install in the reverse order |
|
|
| 21 |
Bleed brake system |
|
AR42.10-P-0010GH |