Vehicles From MY 10.00

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

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

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)
- Functional check
- Separating from brake pedal
- Removing and installing
- Application
- See Parts supplier
- Brake assistant in brake booster
- Function test
- Application
- See Parts supplier
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
- See Parts supplier
10. Sender 1 for brake booster -G201-
- 25 Nm (18 4 ft. lbs.)
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. lbs.)

Sender 1 for brake booster -G201- and Sensor -2- for brake pressure -G214-, removing and installing

Removing
- Request radio code on vehicles with coded radio, if necessary.
- Disconnect battery.
- Lay out sufficient lint free cloths in area of plenum chamber, engine, and transmission.





- Draw off as much brake fluid as possible from brake fluid reservoir using brake filler and bleeder unit VAS 5234.
- Connect bleeding bottle hose to front left brake caliper bleed screw and open bleeding screw.
- Operate brake pedal at least 15 times so that the brake master cylinder empties.
- Close front left bleeder screw.





- Pull connector -arrow- off relevant brake pressure sender (the one to be removed).
a - Sensor -2- for brake pressure -G214- in primary brake circuit
b - Sender 1 for brake booster-G201- in secondary brake circuit
- Remove brake pressure sensor.

Installing
- Installation is carried out in the reverse sequence

Tightening torques:
Sender 1 for brake booster - G201 25 Nm (18 ft. lbs.)
Sensor -2- for brake pressure - G214 25 Nm (18 ft. lbs.)

- Bleeding brake system Mark 60 IE
- Initiate basic settings
- A zero compensation of sender 1 for brake booster-G201- must be performed in addition to basic settings on vehicles with ABS/EDL/ASR/ESP.

Check function of brake assist in brake booster, vehicles from my 02.02
With engine running, depress brake pedal to ensure full vacuum boost.

When brake pedal is depressed, a "click" must be audible, so that the mechanical brake assist is activated.

The brake pedal can now be partially released and pressed again with less force.

It is not possible to repair the brake assist, the complete brake booster must be replaced.