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

MODEL 205 

MODEL 253 

Fig 1: Identifying Brake Booster Remove/Install Components (1 Of 2)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Brake Booster Remove/Install Components (2 Of 2)

Courtesy of MERCEDES-BENZ USA

	Risk of poisoning  from swallowing brake fluid. Risk of injury  from skin and eye contact with brake fluid	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
	Brake fluid notes		AH42.50-P-0001-01A
	Notes on externally invisible brake fluid loss		AH42.10-P-9406-02V
	Notes on repairs to brake system		AH42.00-P-0003-01A
	Remove/install
1	Operate the brake pedal several times when the engine is switched off	In order to reduce the vacuum in the BAS brake booster (A7/7).
2	Remove left and right wiper arms		AR82.30-P-6100LW
3	Remove plenum channel under left and right wiper arm
4	Remove strut (10)	Nut, upper struts to firewall	*BA62.30-P-1002-02K
		Screw/bolt, upper struts to suspension strut tower mounting bracket	*BA62.30-P-1001-02K
5	Remove screws/bolts (2, 8) and take off strut (3)	Screw/bolt, lower strut to firewall	*BA62.30-P-1004-02K
		Screw/bolt, lower strut to suspension strut tower mounting bracket	*BA62.30-P-1003-02K
6	Unscrew cap (4) and remove sieve from brake fluid reservoir (5)
7	Suction off brake fluid from the brake fluid reservoir (5)
8	Disconnect electrical connection (9) from brake fluid level switch
9	Detach feed hose from brake fluid reservoir (5)	If installed. Seal feed hose and brake fluid reservoir (5), and protect painted surfaces from brake fluid. Damage can otherwise be caused by escaping brake fluid.
		Record plug	Fig 4
10	Unscrew nuts (7) of engine fuse and relay module (K40/8)
11	Place engine fuse and relay module (K40/8) with connected lines to one side
	Clean
12	Clean master brake cylinder (6) in area of brake line (12) connections	Before opening the brake system, the area around the separation point should be cleaned thoroughly. Minute dirt particles in the hydraulic components can otherwise lead to malfunctions and a total failure of the brake system. Only use clean, lint free rags and cleaner free of mineral oil. Do not use any compressed-air for cleaning when the brake system is open.
		Assembly cleaner	*BR00.45-Z-1028-04A
13	Mark brake lines (12) according to connections
14	Detach brake lines (12) from master brake cylinder (6)	Seal connection fittings at master brake cylinder (6). Otherwise, foreign objects may enter the master brake cylinder (6) and cause damage.
		Retaining screw, brake line to master brake cylinder	*BA42.10-P-1003-04O
		Record plug	Fig 4
		Box wrench bit	Fig 3
15	Pull brake booster vacuum line (13) from BAS brake booster (A7/7)
16	Detach electrical connection (11) from brake vacuum sensor (B64/1)
17	Remove panel under instrument panel on driver side		AR68.10-P-1500LW
18	Remove guide pin (15) from brake pedal (16)	Brake booster to brake pedal	*BA43.10-P-1002-01J
19	Unscrew nuts (14) from BAS brake booster (A7/7)	Nut, brake booster carrier to front end	*BA43.10-P-1001-01J
20	Push brake lines (12) carefully to one side and remove BAS brake booster (A7/7) from engine compartment	Do not deform the brake lines (12). Deformed brake lines (12) can lead to failure of the brake system. Do not damage boot during removal/installation of BAS brake booster (A7/7). A damaged boot can lead to failure of the BAS brake booster (A7/7).
21	Detach master brake cylinder (6)	When replacing the BAS brake booster (A7/7).
			AR42.10-P-0300LW
22	Install in the reverse order
23	Bleed brake system		AR42.10-P-0010LW
	Check
24	Carry out brake test on the test stand
			AP42.00-P-4290BA

BRAKE LINES, BRAKE HOSES

Number	Designation			Model 205 (except 205.086/087/286/287/387/487)	Model 205.086/087/286/28 7/387/487
BA42.10-P-1003-04O	Retaining screw, brake line to master brake cylinder	Ø 4.75 mm	Nm	18	18
		Ø 6.00 mm	Nm	18	18
		Ø 8.00 mm	Nm	24	24

BRAKE LINES, BRAKE HOSES

Number	Designation			Model 253
BA42.10-P-1003-04O	Retaining screw, brake line to master brake cylinder	Ø 4.75 mm	Nm	16
		Ø 6.00 mm	Nm	16
		Ø 8.00 mm	Nm	-

PNEUMATIC BRAKE BOOSTER

Number	Designation		Model 205	Model 253
BA43.10-P-1001-01J	Nut, brake booster carrier to front end	Nm	22	22

PNEUMATIC BRAKE BOOSTER

Number	Designation		Model 205	Model 253
BA43.10-P-1002-01J	Brake booster to brake pedal	Nm	22	22

FROND END WITH FRONT REINFORCEMENT

Number	Designation		Model 205	Model 253
BA62.30-P-1001-02K	Screw/bolt, upper struts to suspension strut tower mounting bracket	Nm	50	50

FROND END WITH FRONT REINFORCEMENT

Number	Designation		Model 205	Model 253
BA62.30-P-1002-02K	Nut, upper struts to firewall	Nm	23	23

FROND END WITH FRONT REINFORCEMENT

Number	Designation		Model 205	Model 253
BA62.30-P-1003-02K	Screw/bolt, lower strut to suspension strut tower mounting bracket	Nm	50	50

FROND END WITH FRONT REINFORCEMENT

Number	Designation		Model 205	Model 253
BA62.30-P-1004-02K	Screw/bolt, lower strut to firewall	Nm	23	23

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

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Record Plug (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1028-04A	Assembly cleaner	Adolf Wurth GmbH & Co. KG