Remove/install brake booster - AR43.10-P-0350CW

Fig 1: Identifying Brake Booster Components

Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake fluid coming into contact with skin and eyes. Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid. See AS42.50-Z-0001-01A .

Push down brake pedal several times. Until the vacuum in the brake booster A7/7) is reduced.

Open engine hood and raise to vertical position.

Remove strut (3). Model 204.9: Two bolts (1) are installed. See BA32.25-P-1003-04M and BA62.30-P-1007-02G .

Disconnect electrical connector (14) on switch (S11)

Extract brake fluid from brake fluid expansion reservoir

Remove vacuum line (15) starting from connecting point. Installation: replace rubber seal (13). See AR43.10-P-0355CW .

Remove brake lines on master brake cylinder (16). See AR42.10-P-0300CW .

Remove cover (4) from fuse box.

Pry off rubber grommet (5) and put wiring harness (6) to one side.

Detach feed hose for clutch master cylinder on brake fluid expansion reservoir. Vehicles with manual transmission: close off feed hose. See BA43.10-P-1002-01J .

Remove left cover below dashboard.

Separate the electrical connector (7) and unclip line from bracket (8).

Remove cover (9) of brake pedal bearing bracket.

Unscrew locking bolt (17) and remove brake pedal from clevis (18). Installation: Locking bolt (17) has to be replaced.

Unscrew nuts (11) from brake booster (A7/7). See BA43.10-P-1001-01J .

Loosen water collector. Model 204.9: Only remove left wiper arm and lift up water collector in area of brake booster (A7/7) upwards off the seal strip of the windshield.

Remove brake booster (A7/7). Do not deform brake lines. Do not damage the rubber boot (12) when removing and installing the brake booster (A7/7). When removing the brake booster (A7/7) press the brake lines to one side carefully.

Remove master brake cylinder (16). When replacing the brake booster (A7/7), see AR42.10-P-0300CW .

Install in the reverse order.

Carry out brake test on the test stand. See AP42.00-P-4290BA .

BRAKE DISCS, BRAKE COVER PLATE

Number	Designation		Model 204
BA32.25-P-1003-04M	Suspension strut to body	Nm	33

PNEUMATIC BRAKE BOOSTER

Number	Designation		Model 204
BA43.10-P-1001-01J	Nut, brake booster carrier to front end	Nm	20
BA43.10-P-1002-01J	Brake booster to brake pedal	Nm	20