Remove/Install Brake Booster - AR43.10-P-0350LWO
Model 238
MODIFICATION NOTES
| 12.09.2017 | Nut, upper struts to firewall | Model 238 | BA62.30-P-1002-02K |
| 20.04.2018 | Screw/bolt, upper struts to suspension strut tower mounting bracket | Model 238 | BA62.30-P-1001-02K |
| 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 | |
| Remove/install | |||
| 1 | Reduce vacuum in BAS brake booster (A7/7) by operating the brake pedal (16) several times in succession | ||
| 2 | Remove left and right wiper arms | AR82.30-P-6100LW | |
| 3 | Remove air-water-duct under the wiper arms | ||
| 4 | Remove strut (10) | *BA62.30-P-1002-02K | |
| *BA62.30-P-1001-02K | |||
| 5 | Remove bolts (2, 8) and take off strut (3) | *BA62.30-P-1004-02K | |
| *BA62.30-P-1003-02K | |||
| 6 | Cover painted surfaces in the repair area | Protect painted surfaces from brake fluid. Damage can otherwise be caused by escaping brake fluid. |
|
| 7 | Unscrew cap (4) and remove sieve from brake fluid reservoir (5) | Before opening, clean the areas surrounding the cap (4) thoroughly. Otherwise minute particles of dirt in the hydraulic components can result in malfunctions and total failure of the brake system. Assembly cleaner |
*BR00.45-Z-1028-04A |
| 8 | Suction off brake fluid from the brake fluid reservoir (5) | ||
| 9 | Detach hose from brake fluid reservoir (5) and seal openings using suitable stop plugs | Model 238 with transmission 716 |
Fig 3 |
| 10 | Seal brake fluid reservoir (5) | ||
| 11 | Disconnect electrical connection (9) from brake fluid level switch | ||
| 12 | Unscrew nuts (7) of engine fuse and relay module (K40/8) and place engine fuse and relay module (K40/8) with connected lines to one side | ||
| 13 | Clean master brake cylinder (6) in area of brake line (12) connections | Before opening the brake system, the area around the separating point must be cleaned thoroughly. Otherwise minute particles of dirt in the hydraulic components can result in malfunctions and total failure of the brake system. Assembly cleaner |
*BR00.45-Z-1028-04A |
| 14 | Remove brake lines (2) from master brake cylinder (1) | *BA42.10-P-1003-04P | |
| Fig 2 | |||
| 15 | Seal connection fittings on master brake cylinder (1) and brake lines (2) | Fig 3 | |
| 16 | Pull vacuum line (13) out of brake booster (A7/7) | ||
| 17 | Detach electrical connection (11) from brake vacuum sensor (B64/1) | ||
| 18 | Remove panel under instrument panel on driver side | AR68.10-P-1501LWE | |
| 19 | Remove guide pin (15) from brake pedal (16) | *BA43.10-P-1002-01J | |
| 20 | Unscrew nuts (14) from BAS brake booster (A7/7) | *BA43.10-P-1001-01J | |
| 21 | 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. |
|
| 22 | Remove master brake cylinder (6) | When replacing the BAS brake booster (A7/7). | AR42.10-P-0300LWO |
| 23 | Install in the reverse order | ||
| 24 | Bleed brake system | AR42.10-P-0010LWE | |
| Check | |||
| 25 | Carry out brake test on the test stand | ||
| AP42.00-P-4290BA |
BRAKE LINES, BRAKE HOSES
| Number | Designation | Model 238 | |
|---|---|---|---|
| BA42.10-P-1003-04P | Retaining screw, brake line to master brake cylinder | Nm | 16 |
PNEUMATIC BRAKE BOOSTER
| Number | Designation | Model 238 | |
|---|---|---|---|
| BA43.10-P-1001-01J | Nut, brake booster carrier to front end | Nm | 22 |
PNEUMATIC BRAKE BOOSTER
| Number | Designation | Model 238 | |
|---|---|---|---|
| BA43.10-P-1002-01J | Brake booster to brake pedal | Nm | 22 |
FROND END WITH FRONT REINFORCEMENT
| Number | Designation | Model 238 | |||
|---|---|---|---|---|---|
| BA62.30-P-1001-02K | Screw/bolt, upper struts to suspension strut tower mounting bracket | Stage 1 | Nm | 35 | |
| Stage 2 | Nm | 50 | |||
| Stage 3 | Loosen | ∠° | 180 | ||
| Stage 4 | Nm | 50 | |||
FROND END WITH FRONT REINFORCEMENT
| Number | Designation | Model 238 | |
|---|---|---|---|
| BA62.30-P-1002-02K | Nut, upper struts to firewall | Nm | 35 |
FROND END WITH FRONT REINFORCEMENT
| Number | Designation | Model 238 | |
|---|---|---|---|
| BA62.30-P-1003-02K | Screw/bolt, lower strut to suspension strut tower mounting bracket | Nm | 50 |
FROND END WITH FRONT REINFORCEMENT
| Number | Designation | Model 238 | |
|---|---|---|---|
| BA62.30-P-1004-02K | Screw/bolt, lower strut to firewall | Nm | 23 |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1028-04A | Assembly cleaner | A 000 986 56 01 |