Vehicles Up to MY 9.00

Brake booster/brake master cylinder for vehicles with ABS/EDL/ASR/ESP, servicing for vehicles up to my 9.00

Note: Complete brake master cylinder and brake booster can be replaced independently of each other.

1. Brake booster
- With wiring harness, Sender -1- for Brake booster -G201-, Sensor -2- for Brake Pressure -G214-, item 12
- On gasoline engines, the required vacuum is drawn at the intake manifold
- On diesel engines, a vacuum pump is installed to generate a vacuum
- Function testing
- With engine off, push brake pedal down all the way forcefully several times (this reduces the vacuum present in the equipment)
- Now hold brake pedal in braking position with medium foot pressure and start engine. If the brake booster functions properly, the pedal will be felt to give slightly under foot (booster takes effect).
- If there are malfunctions, replace completely.
- Check valve (in vacuum hose)
- Function testing
- Disconnecting from brake pedal
- Removing and installing
2. Bracket
- Mounted on edge or brake booster
- Used to hold the connector housing -Item 14
3. Cover
4. Brake fluid reservoir
5. Sealing stopper
- Coat with brake fluid and press into expansion tank
6. Holding pin
- Insert through the brake master cylinder
7. Brake master cylinder
- Can not be repaired. Replace complete if there are malfunctions.
8. Holding plate
- Used to fasten the wiring harness
9. Hex nut, self-locking 20 Nm
10. Heat shield plate
- Only on vehicles with 74 kW, 92 Kw, 110 kW, 150 kW engines
- See Parts supplier
11. Sender -1- for Brake Booster -G201-
- Removing and installing
12. Sender -2- for Brake Pressure -G214-m
- Removing and installing
13. Sealing ring
- Always replace
14. Connecting housing
15. Wiring harness
16. Vacuum hose
- Install in brake booster
17. Sealing plug
18. Seal
- for brake booster
19. Hex nut, self-locking, 20 Nm
20. Boot
- Make sure correct seat, danger of suction noises

Vacuum pump for brake booster, removing and installing (vehicles with Diesel engines)

Removing
- Remove retainer for wiring harness from vacuum pump.





- Loosen vacuum hose clamp (arrow -A-) and remove hose from pump.
- Remove bolts (arrow -B-) on flange.
- Remove vacuum pump.

Note: The vacuum pump cannot be repaired.

Installing

Note: When installing the vacuum pump be sure that the follower engages correctly with the camshaft.





- Install bolts (arrows -B-) on cylinder head flange.
- Secure vacuum hose with clamp (arrow -A-).





- Check function of check valve -A-.
- Air must pass through in direction of arrow.
- Valve must remain closed in opposite direction.
- Make sure that the check valve is installed correctly.