Brake booster/brake master cylinder for vehicles with ABS/EDL/ASR/ESP Mark 60 from m.y. 10.00, assembly overview

1 - Brake booster 

• On gasoline engines the vacuum required is taken from the intake manifold.
• On Diesel engines a vacuum pump is installed to create the required vacuum.
• On some vehicles an electrical brake system vacuum pump -V192- is installed
• Functional check

• With engine not running, depress brake pedal firmly several times (to exhaust the vacuum in the unit).

• Now depress brake pedal with average foot pressure, hold and start engine. If the brake booster is working properly, the pedal will be felt to give slightly under foot (booster assistance becomes effective).

• If faulty, replace complete
• Non-return valve (in vacuum hose). Refer to Check function of check valve -A-. 

Functional check. Refer to Brake system vacuum pump -V192-, removing and installing 

• Separating from brake pedal. Refer to Brake master cylinder, removing and installing 
• Removing and installing. Refer to Brake master cylinder, removing and installing 
• Brake assistant in brake booster
• Function test. Refer to Check function of brake assist in brake booster, vehicles from my 02.02, 

2 - Sealing cap 

3 - Brake fluid reservoir 

4 - Sealing plugs 

• Coat with brake fluid and install into brake fluid reservoir

5 - Retaining pin 

• Insert through brake master cylinder

6 - Brake master cylinder 

• Must not be repaired. If faulty, replace complete.

7 - Retaining plate 

• Used to secure the wiring harness

8 - Self locking nut, 20 Nm 

9 - Heat shield 

• Application

10 - Sender 1 for brake booster -G201- 

• 25 Nm (18.4 ft. lb)
• Removing and installing. Refer to

11 - Sealing ring 

• Always replace

12 - Sealing plug 

• Connection for vacuum hose

• Insert into brake servo unit

13 - Gasket 

• For brake booster

14 - Self-locking hex nut, 20 Nm (14 ft. lb)