Remove/Install Brake Booster - AR43.10-P-0350FR
Model 257
Model 290
MODIFICATION NOTES
| 20.04.2018 | Screw/bolt, upper struts to suspension strut tower mounting bracket | Model 257 | BA62.30-P-1001-02K |
Shown on model 257
| 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 | |
| Topical note | Notes on externally invisible brake fluid loss | AH42.10-P-9406-02A | |
| Topical note | Brake fluid notes | AH42.50-P-0001-01A | |
| Topical note | Notes on repairs to brake system | AH42.00-P-0003-01A | |
| Notes on safety-relevant components | AH00.00-Z-0019-01A | ||
| Remove/install | |||
| 1 | Reduce vacuum in BAS brake booster (A7/7) by operating the brake pedal (16) several times. | ||
| 2 | Remove left and right wiper arm. | AR82.30-P-6100FR | |
| 3 | Remove air/water duct on driver's side. | ||
| 4 | Remove air/water duct on front passenger side. | ||
| 5 | Remove air/water duct under the wiper arms. | ||
| 6 | Remove strut (10). | ||
| Topical note | Notes on threaded connections fastened using a tightening angle-based tightening process | AH00.00-P-0020-01A | |
| *BA62.30-P-1002-02K | |||
| *BA62.30-P-1001-02K | |||
| 7 | Remove screws (2, 8) and take off strut (3). | *BA62.30-P-1004-02K | |
| *BA62.30-P-1003-02K | |||
| 8 | Cover painted surfaces in the repair area. | Protect painted surfaces from brake fluid. Damage can otherwise be caused by escaping brake fluid. |
|
| 9 | Clean area around the cap (4) on brake fluid reservoir (5). | Before opening, clean area around the cap (4) thoroughly. Otherwise dirt particles in the hydraulic component parts can result in malfunctions and total failure of the brake system. |
|
| Assembly cleaner | *BR00.45-Z-1028-04A | ||
| 10 | Unscrew cap (4) and remove sieve from brake fluid reservoir (5). | ||
| 11 | Extract brake fluid from brake fluid reservoir (5). | ||
| 12 | Seal brake fluid reservoir (5). | ||
| 13 | Disconnect electrical connector (9) from brake fluid level switch. | ||
| 14 | Unscrew nuts (7) and place engine fuse and relay module (K40/8) with connected lines to one side. | ||
| 15 | Clean master brake cylinder (6) in the area of the connections of the brake lines (12). | Thoroughly clean area around connecting points before opening the brake system. Otherwise minute dirt particles in the hydraulic component parts can result in malfunctions and total failure of the brake system. |
|
| Assembly cleaner | *BR00.45-Z-1028-04A | ||
| 16 | Remove brake lines (12) from master brake cylinder (6). | ||
| Note on calculation of tightening torque when using insertion or socket tools with various | AH00.00-P-0015-01CW | ||
| *BA42.10-P-1003-04P | |||
| effective lengths | Fig 2 | ||
| 17 | Seal connection fittings on master brake cylinder (6) and brake lines (12). | Fig 1 | |
| 18 | Pull vacuum line (13) out of BAS brake booster (A7/7). | ||
| 19 | Disconnect electrical connector (11) from brake vacuum sensor. | ||
| 20 | Remove trim under instrument panel on driver's side. | AR68.10-P-1501FR | |
| 21 | Remove guide pin (15) from brake pedal (16). | *BA43.10-P-1002-01J | |
| 22 | Unscrew nuts (14) of BAS brake booster (A7/7). | *BA43.10-P-1001-01J | |
| 23 | 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). Otherwise the brake system may malfunction. Do not damage boot during removal/installation of BAS brake booster (A7/7). Otherwise the BAS brake booster (A7/7) may malfunction. |
|
| 24 | Remove master brake cylinder (6). | When replacing the BAS brake booster (A7/7) | AR42.10-P-0300FR |
| 25 | Install in the reverse order. | ||
| 26 | Bleed brake system. | AR42.10-P-0010FR | |
| Check | |||
| 27 | Perform brake test on test stand. | ||
| AP42.00-P-4290BA |
BRAKE LINES, BRAKE HOSES
| Number | Designation | Model 257 | Model 290.658/659/661 except code B07/U69 | |
|---|---|---|---|---|
| BA42.10-P-1003-04P | Retaining screw, brake line to master brake cylinder | Nm | 16 | 16 |
BRAKE LINES, BRAKE HOSES
| Number | Designation | Model 290.658/659/661 with code B07/U69, model 290.679/688/689 | |
|---|---|---|---|
| BA42.10-P-1003-04P | Retaining screw, brake line to master brake cylinder | Nm | 16 |
PNEUMATIC BRAKE BOOSTER
| Number | Designation | Model 257 | Model 290 | |
|---|---|---|---|---|
| BA43.10-P-1001-01J | Nut, brake booster carrier to front end | Nm | 22 | 22 |
PNEUMATIC BRAKE BOOSTER
| Number | Designation | Model 257 | Model 290 | |
|---|---|---|---|---|
| BA43.10-P-1002-01J | Brake booster to brake pedal | Nm | 22 | 22 |
FROND END WITH FRONT REINFORCEMENT
| Number | Designation | Model 257 | Model 290 | |||
|---|---|---|---|---|---|---|
| BA62.30-P-1001-02K | Screw/bolt, upper struts to suspension strut tower mounting bracket | Stage 1 | Nm | 35 | 35 | |
| Stage 2 | Nm | 50 | 50 | |||
| Stage 3 | Loosen | ∠° | 180 | 180 | ||
| Stage 4 | Nm | 50 | 50 | |||
FROND END WITH FRONT REINFORCEMENT
| Number | Designation | Model 257 | Model 290 | |
|---|---|---|---|---|
| BA62.30-P-1002-02K | Nut, upper struts to firewall | Nm | 35 | 23 |
FROND END WITH FRONT REINFORCEMENT
| Number | Designation | Model 257 | Model 290 | |
|---|---|---|---|---|
| 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 257 | Model 290 | |
|---|---|---|---|---|
| BA62.30-P-1004-02K | Screw/bolt, lower strut to firewall | Nm | 23 | 23 |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1028-04A | Assembly cleaner | A 000 986 56 01 |