Brake Servo/Brake Master Cylinder

Brake Servo/Brake Master Cylinder

Assembly Overview

Note: Use only new brake fluid. Read information on brake fluid reservoir!





1 - T45 torx socket head bolt, 25 Nm
2 - Self-locking hex nut, 49 Nm
3 - Sealing plug
^ Coat with brake fluid and press into brake fluid reservoir
4 - Brake fluid reservoir
5 - Oil seal
6 - Cap
7 - Supply hose
^ From brake fluid reservoir to clutch master cylinder
8 - Vacuum hose
^ Insert into brake servo unit
9 - Tandem brake servo
^ Adjusting ball plunger Fig. 1
^ On gasoline engines the vacuum required is taken from the intake manifold.
^ From model year 2001, vehicles with a gasoline engine and automatic transmission are equipped with a brake vacuum pump
^ Functional check
- With engine switched off, depress brake pedal firmly several times (to exhaust the vacuum in the unit).
- Depress brake pedal with average foot pressure, hold and start engine. If the servo unit is working properly, the pedal will drop slightly (servo assistance becomes effective).
10 - Seal
11 - Bulkhead
12 - Sealing ring
^ Always replace
13 - Brake line
^ Master brake cylinder/primary piston circuit to hydraulic unit
14 - Brake line
^ Master brake cylinder/secondary piston circuit to hydraulic unit
15 - Hex bolt
16 - Tandem brake master cylinder
^ Cannot be repaired. If faulty, replace.





Fig. 1 Adjusting ball plunger
A = 159 mm ± 0.5 mm

Notes:
^ When measuring the ball plunger it must be set at right angles to the surface of the brake servo.
^ Measure to end of ball plunger without gasket installed.