Remove/install BAS diaphragm travel sensor - AR42.31-P-6002P

MODEL 203, 209 

Shown on model 203 

Fig 1: Identifying BAS Diaphragm Travel Sensor Remove/Install Components (Shown On Model 203)

MODIFICATION NOTES

1.3.04

Disconnect/connect ground line on battery

	Remove/install
1	Operate brake pedal several times until vacuum in brake booster is reduced.	The sealing ring of the BAS diaphragm travel sensor (A7/7b1) can be sucked into the brake booster under vacuum. If this is the case the brake booster must be replaced.
	Notes on brake booster		AH43.20-P-0001-01A
2	Remove tandem master brake cylinder		AR42.10-P-0310P
3	Disconnect diaphragm travel sensor connector (A7/7x1)
4	Remove circlip (16b)	Use a suitable tool e.g. an angled scriber (arrow). Installation:  Replace the circlip (16b) and pay attention to correct seating. Only use the circlip (16b) which is approved by the manufacturer.
	Notes on brake booster		AH43.20-P-0001-01A
5	Pull out diaphragm travel sensor BAS (A7/7b1).	Installation:  Rub the BAS diaphragm travel sensor (A7/7b1) at the front slightly with spirit or with soapy water so that the O-ring can be inserted more easily.
6	Replace O-ring	Installation:  Insert O-ring into groove of brake booster and check for proper seating.
7	Install in the reverse order
	Checking
8	Start engine	Operate brake several times.
9	Turn off engine
10	Check leaktightness of BAS diaphragm travel sensor (A7/7b1)	Air flow noises must not be audible at the brake booster.
11	Connect STAR DIAGNOSIS, read out and erase fault memory
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04A
		STAR DIAGNOSIS diagnosis system	*WH58.30-Z-1048-13A

COMMERCIALLY AVAILABLE TOOLS

Number	Designation
WH58.30-Z-1048-13A	STAR DIAGNOSIS diagnosis system, Compact Passenger Car	6511 1801 00