Preliminary Work

WARNING: This page is about a different variant/trim than selected.

Remove cross panel.
> WM, 508119 REMOVING AND INSTALLING CROSS PANEL (DISASSEMBLING PLENUM PANEL)

WARNING: Danger of injury and damage from brake fluid!

Poisonous if swallowed!
Irritation and damage to skin
Avoid contact with paint surfaces
1. Store brake fluid in suitable, labelled containers only
2. Wear protective gloves and goggles
3. In the event of contact (eyes or skin), wash immediately with water
4. In the event of contact with paint surfaces, wash off immediately with water - do not wipe off

Information

When carrying out work during which fluids can escape, electric plug connections to be disconnected must remain locked and connected for as long as possible. This prevents fluid from getting onto electric contacts and causing corrosion.

Information

Brake fluid - even thinned brake fluid - causes corrosion on electric contacts, thereby impairing functions.

Have suitable aids ready for soaking up escaping fluids.
Have suitable stoppers ready for closing off the line connections.
Disconnect vacuum lines -1- from plastic bracket -2- .

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Vacuum lines on plastic bracket
1. 3.1 Unclip clip -3- .
2. 3.2 Release quick connectors -4 and 5- and disconnect vacuum lines.
3. 3.3 Unclip vacuum lines -1- from plastic bracket -2- and remove plastic bracket -2- .
Disconnect brake pedal -1- from brake booster push rod -2- .

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Brake booster push rod on brake pedal
1. 4.1 Press the brake pedal -1- towards the brake booster with your hand -arrow A- .
2. 4.2 > T40136 - release tool must be positioned at the retaining lugs -3- of the ball joint mounting.
3. 4.3 Release retaining lugs of the ball joint mounting -3- by moving them towards the driver seat using > T40136 - release tool and counter at the brake pedal -1- at the same time (the brake pedal must not move towards the driver seat).
4. 4.4 Separate the brake pedal -1- from the push rod using > T40136 - release tool by moving it towards the driver seat -arrow B- .
Drain the brake fluid reservoir.
1. 5.1 Unscrew cap on brake fluid reservoir.
2. 5.2 Extract brake fluid from brake fluid reservoir using a syringe.
3. 5.3 Screw on cap on brake fluid reservoir.
4. 5.4 Clean off any escaping brake fluid immediately using suitable cleaning aids.
  Wash affected components again with water and dry them.
Information

Any escaping brake fluid must be removed immediately. If necessary, rinse contacts with water and dry them.
Disconnect brake lines -1- on the brake master cylinder -2- .

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Brake lines on brake master cylinder
1. 6.1 Place suitable aids underneath the brake master cylinder -2- to catch escaping brake fluid.
2. 6.2 Unscrew union nuts on brake lines -3- and disconnect brake lines -1- from the brake master cylinder -2- .
3. 6.3 Close off line connections using stoppers and move brake lines -1- aside carefully.
4. 6.4 Close off connections on brake master cylinder -2- using stoppers.
Disconnect vacuum connection -1- from brake booster -2- and set it down on the side.

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Vacuum connection
Release and disconnect electric plug connection -1- .

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Electric plug connection
Detach brake booster -1- .

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Screws on brake booster
1. 9.1 Unscrew screws -2- .
Pull brake booster -1- together with the brake master cylinder and brake fluid reservoir forward -Arrow- and guide them up out of the technical equipment space.

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Brake booster