Remove/install pedal assembly - AR29.10-P-0300P

MODEL 203 with TRANSMISSION 716.6

Fig 1: Identifying Pedal Assembly Remove/Install Components - Model 203 With Transmission 716.6 (1 Of 3)

Fig 2: Identifying Pedal Assembly Remove/Install Components - Model 203 With Transmission 716.6 (2 Of 3)

Fig 3: Identifying Pedal Assembly Remove/Install Components - Model 203 With Transmission 716.6 (3 Of 3)

MODIFICATION NOTES

21.3.03

The pedal assembly can only be removed with the master cylinder

Procedure completely modified

	Remove/Install
	Risk of death. Death may result if vehicle slips or topples from the lifting platform	Align vehicle between the columns of the hydraulic hoist and position the four support plates below the hoist support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
	Risk of poisoning from swallowing brake fluid. Risk of injury from 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 203	AH42.10-P-9406-02A
1	Remove cover below instrument panel (on left)		AR68.10-P-1500P
2	Remove sound absorber (7)
3.1	Remove stop lamp switch	Model 203 up to date of manufacture 31.7.01
4	Remove cover (6).
5	Suction off brake fluid from expansion reservoir	Suction off brake fluid as far as the connection of the connector hose (8).
6	Pull the connector hose (8) off the expansion reservoir
7	Detach lower engine compartment paneling	Engine 112, 113, 271 Only remove the rear section.	AR61.20-P-1105P
8	Remove bottom sections of noise encapsulation	Engine 612 Only remove the rear section.	AR94.30-P-5300P
9	Open bleed screw on central clutch operator	Collect brake fluid in a suitable container. Suction off brake fluid out of the line with the help of an assistant.
		Socket wrench	Fig 4
10	Pull out retaining clamp (9) at the connecting pipe of the master cylinder	Avoid brake fluid and soiling in interior. Otherwise parts of the interior may become damaged.
11	Disconnect coupling (1) from clutch pedal switch (S40/3)
12	Press retainer (2) off pin (3)
13	Pull out pin (3)	Check pin for damage and wear; replace if necessary.
		Installation: Lightly grease pin.	*BR00.45-Z-1001-06A
14	Unscrew collared nuts (4)	Nut, brake booster carrier to front end	*BA43.10-P-1002-01A
15	Remove pedal assembly	Do not damage wiring harness.
16	Pull out line at the connecting pipe of the master cylinder	Installation: Replace O-ring (10).
17	Pull connector hose (8) into the interior	Installation: When installing ensure that the grommet (11) is seated correctly.
18	Install in the reverse order	Do not install engine compartment paneling or lower part of noise encapsulation yet.
19	Bleed clutch actuation		AR25.20-P-0070P
20	Install lower engine-compartment encapsulation panel	Engine 112, 113, 271 Only remove the rear section.	AR61.20-P-1105P
21	Install lower parts of noise encapsulation	Engine 612 Only remove the rear section.	AR94.30-P-5300P

PNEUMATIC BRAKE BOOSTER

Number	Designation		Model 203
BA43.10-P-1002-01A	Nut, brake booster carrier to front end	NM	20

Fig 4: Identifying Socket Wrench (140 589 03 09 00)

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1001-06A	Long-life grease	A 000 989 63 51