Remove/install stepped tandem master brake cylinder - AR42.10-P-0310P

MODEL 203, 209

Shown on model 203 up to 31.07.01

Fig 1: Identifying Stepped Tandem Master Brake Cylinder Remove/Install Components (Shown On Model 203 Up To 31.07.01)

Shown on model 203 as of 01.08.01

Fig 2: Identifying Stepped Tandem Master Brake Cylinder Remove/Install Components (Shown On Model 203 As Of 01.08.01)

MODIFICATION NOTES

1.3.04

Disconnect/connect ground line on battery

	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		AH42.50-P-0001-01A
	Notes on repairs to brake system		AH42.00-P-0003-01A
	Notes on externally invisible brake fluid loss		AH42.10-P-9406-02A
1	Disconnect electrical connector (20) from brake fluid indicator switch (S11)
2	Suction off brake fluid from brake fluid reservoir (10)
3	Disconnect brake lines (5)	Seal off connections with plugs.
			*BA42.10-P-1003-04A
			Figure
4.1	Disconnect electrical connector on ESP pressure sensor 2 (B34/2) and remove ESP pressure sensor 2 (B34/2)	Model 203 up to date of manufacture 31.7.01
4.2	Disconnect electrical connector on ESP brake pressure sensor (B34) and remove ESP brake pressure sensor (B34)	Model 203 as of production date 1.8.01, Model 209 with code 472 Electronic Stability Program (ESP)	AR42.45-P-0816Q
5	Detach clutch master cylinder hose (7)	Vehicles with manual transmission.
6	Remove pendulum support from stepped tandem brake master cylinder (1)	On vehicles which have been involved in accidents with deformations in the front end area the pendulum support must be checked for unobstructed movement.	AR42.10-P-0300-02P
7	Unscrew nuts (19) from brake booster (16)		*BA42.10-P-1001-05A
8	Pull stepped tandem brake master cylinder (1) off threaded studs and turn to the side	Do not tilt stepped tandem brake master cylinder (1), but pull out from the front otherwise the thrust rod no longer makes axial contact and can break free of the retaining lugs at the master control unit.
9	Disconnect electrical connector on ESP pressure sensor 1 (B34/1) and remove ESP pressure sensor 1 (B34/1)	Model 203 up to date of manufacture 31.07.01
10	Remove stepped tandem master brake cylinder (1)	Installation: Install new gasket (17) to ensure that the brake booster (16) functions correctly.
11	Unscrew screw (10a)
12	Pull brake fluid reservoir (10) out of the stepped tandem brake master cylinder (1)	Check reservoir plugs (9) replace if necessary in order to avoid leaks
13	Install in the reverse order
14	Bleed brake system		AR42.10-P-0010P

MASTER BRAKE CYLINDER

Number	Designation		Model 203	Model 209
BA42.10-P-1001-05A	Nut, brake master cylinder to brake booster	Nm	20	25

BRAKE LINES, BRAKE HOSES

Number	Designation		Model 203	Model 209
BA42.10-P-1003-04A	Brake pipe to master brake cylinder	Nm	16	16

Fig 3: Identifying Box Wrench Bit (000 589 75 03 00)