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

MODEL 463.244 /245 /247 /248 /250 /254 /309 /332 /333 as of 30.9.01, 463.322 /323 /243 /246 /249 /270 /271 

Fig 1: Identifying BAS Diaphragm Travel Sensor Remove/Install Components

Courtesy of MERCEDES-BENZ USA

	Remove/Install
	Notes on brake booster	Model 129, 140, 168, 170, 202, 203, 208, 209, 210, 463	AH43.20-P-0001-01A
1	Operate brake pedal several times until vacuum in brake booster is reduced.	The diaphragm travel sensor sealing ring may be sucked into brake booster if vacuum is present. In this case a new brake booster must be installed.
2	Remove ground bolt (14) for jump-starting point ground line.
3	Disconnect diaphragm travel sensor connector (A7/7x1).
4	Remove circlip (16b) using a suitable tool.	Installation: Install new circlip (16b) and ensure it is seated correctly.
5	Remove BAS diaphragm travel sensor (A7/7b1).	Installation:  Lubricate BAS diaphragm travel sensor (A7/7b1) slightly at front using spirit or soapy water.
6	Remove O-ring from brake booster	Installation:  Insert O-ring into groove of brake booster and ensure it is seated correctly.
7	Install in the reverse order
	Check
8	Start engine and actuate brake several times
9	Stop engine running
10	Check diaphragm travel sensor (A7/7b1) for leaks.	There must not be any air flow noises audible at the brake booster.