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

MODEL 204, 207 

Fig 1: Identifying Brake Booster Remove/Install Components

Courtesy of MERCEDES-BENZ USA

MODIFICATION NOTES

5.8.10

"Perform brake test on test bench" reference changed

Test sequence augmented/revised

	Remove/install
	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.	AS42.50-Z-0001-01A
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
1	Push down brake pedal several times	Until the vacuum in the brake booster (A7/7) is reduced.
2	Open engine hood and raise to vertical position	Model 204
		Model 207	AR88.40-P-1000EW
3	Detach wiper arms	Model 207	AR82.30-P-6100CW
4	Remove water collector	Model 207 Do not disconnect electric feed lines and hoses of windshield washer nozzles.
5	Remove strut (3)	Model 204.9: Two bolts (1) are installed.
			*BA32.25-P-1003-04M
		Model 207	*BA62.30-P-1007-02G
6	Disconnect electrical connector (14) on switch (S11)
7	Extract brake fluid from brake fluid expansion reservoir
8	Remove vacuum line (15) starting from connecting point	Replace rubber seal (13).	AR43.10-P-0355CW
9	Remove brake lines on master brake cylinder (16)	Model 204	AR42.10-P-0300CW
		Model 207	AR42.10-P-0300EW
	Brake fluid notes		AH42.50-P-0001-01A
10	Remove cover (4) from fuse box
11	Pry off rubber grommet (5) and put wiring harness (6) to one side
12	Detach feed hose for clutch master cylinder on brake fluid expansion reservoir	Vehicles with manual transmission Close off feed hose.
			Fig 2
13	Remove left cover below dashboard
14	Separate the electrical connector (7) and unclip line from bracket (8)
15	Remove cover (9) of brake pedal bearing bracket
16	Unscrew locking bolt (17) and remove brake pedal from clevis (18)	Locking bolt (17) has to  be replaced.
			*BA43.10-P-1002-01J
17	Unscrew nuts (11) from brake booster (A7/7)		*BA43.10-P-1001-01J
18	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
19	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.
20	Remove master brake cylinder (16)	When replacing the brake booster (A7/7)
		Model 204	AR42.10-P-0300CW
		Model 207	AR42.10-P-0300EW
21	Install in the reverse order
22	Carry out brake test on the test stand		AP42.00-P-4290BA

SUSPENSION STRUTS

Number	Designation		Model 204.00/02/04/05/0 6/20/22/24/25/30/33/34/35 without code 483	Model 204.00/02/04/05/06/20/22/24/25/30/33/34/35 with code 483, model 204.077/277/377
BA32.25-P-1003-04M	Suspension strut to body	Nm	33	33

SUSPENSION STRUTS

Number	Designation		Model 204.08/09/28/29/38/9
BA32.25-P-1003-04M	Suspension strut to body	Nm	33

SUSPENSION STRUTS

Number	Designation		Model 207 without code 483	Model 207 with code 483
BA32.25-P-1003-04M	Suspension strut to body	Nm	33	33

FRONT END ASSEMBLY WITH FRONT REINFORCEMENT

Number	Designation		Model 207.3	Model 207.4
BA62.30-P-1007-02G	Nut, strut to firewall	Nm	35	35

PNEUMATIC BRAKE BOOSTER

Number	Designation		Model 204	Model 207
BA43.10-P-1001-01J	Nut, brake booster carrier to front end	Nm	20	20
BA43.10-P-1002-01J	Brake booster to brake pedal	Nm	20	20

Fig 2: Identifying Set Of Stop Plugs (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA