Procedures

Remove/Install BAS Diaphragm Travel Sensor

Shown On Model 203:

Remove/Install

DANGER:
- Risk of explosion from hydrogen gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury to eyes and skin suffering caustic burns from battery electrolyte or from contact with damaged lead acid batteries.
- No fire, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and glasses. Pour battery electrolyte only into suitable and appropriately marked containers.

1 Disconnect ground cable of battery

2 Operate brake pedal several times until vacuum in brake booster is reduced.

CAUTION:
- Seal of diaphragm travel sensor may be sucked into brake booster if vacuum is present.
- If this is the case the brake booster must be replaced.

NOTE: See notes on brake booster

3 Remove tandem master brake cylinder
4 Unplug BAS diaphragm travel sensor connector (A7/7x1)
5 Remove circlip (16b)
- Use a suitable tool e.g. an angled scriber (arrow).

NOTE: Installation: Install new circlip and ensure circlip is seated correctly.

6 Pull out BAS diaphragm travel sensor (A7/7b1)

NOTE: Installation: Rub the diaphragm travel sensor at the front with some spirit or soap suds so that when inserting the O-ring slides correctly.

7 Replace O-ring

NOTE: Installation: insert O-ring into groove of brake booster ensure correctly located.

8 Install in the reverse order

Inspecting
9 Start engine

NOTE: Operate brake several times.

10 Switch off engine
11 Check diaphragm travel sensor for tightness

NOTE: Air flow noises must not be audible at the brake booster.

12 Perform basic programming
13 Read diagnostic trouble code memory and erase