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

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MODEL 212, 218 

Fig 1: Brake Booster Remove/Install Components
G09976634Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES

10.8.10 Value changed: Nut for strut to suspension strut tower   *BA62.30-P-1006-02G 
11.8.10 "Perform brake test on test bench" reference changed Test sequence augmented/revised  
REMOVINGINSTALLING Remove/install     
DANGER 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 Notes on self-locking nuts and bolts   AH00.00-N-0001-01A
NOTES Brake fluid notes   AH42.50-P-0001-01A
1 Push down brake pedal several times IMPORTANT Until the vacuum in the BAS brake booster (A7/7) has been reduced.  
2 Open engine hood Model 218  
Model 212 AR88.40-P-1000EW
3 Remove strut (3) TORQUE SPECIFICATION *BA62.30-P-1006-02G 
4 Disconnect electrical connector (5)    
5 Pull vacuum line (15) out of BAS brake booster (A7/7) and place to one side    
6 Remove brake lines on master brake cylinder (16)   AR42.10-P-0300EW
7 Pull feed hose (6) for clutch master cylinder off brake fluid expansion reservoir (4) Only in case of vehicles with manual transmission.
IMPORTANT Seal feed hose (6).
AR25.20-P-0100-01V
SPECIAL TOOL Set of stop plugs Fig 2
8 Remove left cover below dashboard    
9 Detach electrical connector from mechanical brake light switch    
10 Remove cover above pedal assembly If necessary.  
11 Unscrew safety bolt (17) and remove brake pedal from clevis (18) INSTALLATION IMPORTANT Locking bolt (17) has to be replaced.  
TORQUE SPECIFICATION *BA43.10-P-1002-01J 
12 Unscrew nuts (11) from BAS brake booster (A7/7) TORQUE SPECIFICATION *BA43.10-P-1001-01J 
13 Remove water collector over wiper system IMPORTANT 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 AR82.30-P-6400CW
14 Remove brake booster (A7/7) NOTES Do not deform brake lines.
NOTES Do not damage the rubber boot (12) when removing and installing BAS brake booster (A7/7).
IMPORTANT When removing the BAS brake booster (A7/7), carefully push the brake lines to one side.
 
15 Remove master brake cylinder (16) When replacing the BAS brake booster (A7/7). AR42.10-P-0300EW
16 Remove rubber seal (13) When replacing the BAS brake booster (A7/7).  
17 Install in the reverse order    
18 Carry out brake test on the test stand   AP42.00-P-4290BA
PNEUMATIC BRAKE BOOSTER

Number Designation Model 212 Model 218
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
FRONT END ASSEMBLY WITH FRONT REINFORCEMENT

Number Designation Model 212 Model 218
BA62.30-P-1006-02G Nut, strut to suspension strut tower Nm 30 30
Fig 2: Identifying Set Of Stop Plugs (129 589 00 91 00)
G09976635Courtesy of MERCEDES-BENZ USA