Hydraulic Unit, Brake Booster/Brake Master Cylinder Overview

Hydraulic unit, brake booster/brake master cylinder -assembly overview Mark 60

Note: Complete master cylinder and brake booster can be replaced independently of each other.
1. Brake booster, left-hand drive
^ 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 module).
- Now depress brake pedal with average foot pressure, hold and start engine. If the booster module is working properly, the pedal will be felt to give slightly under foot (booster assistance becomes effective).
2. Sealing cap
3. Brake fluid reservoir, left-hand drive (LHD)
4. Sealing plugs
^ Moisten with brake fluid and install into brake fluid reservoir
5. Retaining pin
^ Insert through brake master cylinder
6. Brake master cylinder, left-hand drive (LHD)
^ Must not be repaired. If faulty, replace complete.
7. Brake line
^ Brake master cylinder (primary circuit) to hydraulic unit
8. Connection for brake line
^ Hydraulic unit to left front brake caliper
9. Connection for brake line
^ Hydraulic unit to right front brake caliper
10. Brake line
^ Brake master cylinder (secondary circuit) to hydraulic unit
11. Control module
^ Do not disconnect connector before performing On Board Diagnosis (OBD)
12. Hydraulic unit ABS/EDL
13. Bracket
14. Hex nut, 20 Nm (15 ft. lbs.)
15. Bolts, 8 Nm (70 inch lbs.)
16. Torx socket head bolt E5, 4 Nm (35 inch lbs.)
17. Connection for brake line
^ Hydraulic unit to left rear wheel cylinder/brake caliper
18. Connection for brake line
^ Hydraulic unit to right rear wheel cylinder/brake caliper
19. Brake fluid reservoir, right-hand drive (RHD)
20. Sealing plugs
^ Moisten with brake fluid and install into brake fluid reservoir
21. Bleed valve
22. Retaining plate
^ Used to secure the wiring harness
23. Self-locking hex nut, 20 Nm (15 ft. lbs.)
24. Brake master cylinder, right-hand drive (RHD)
^ Must not be repaired. If faulty, replace complete.
25. Sender 1 for brake booster -G201
26. Bolt
^ To secure brake fluid reservoir to brake master cylinder
27. Seal
^ Always replace
28. Brake booster, right-hand drive
29. Seal
^ For brake booster
30. Self-locking hex nut, 20 Nm (15 ft. lbs.)
31. Boots
^ Make sure boots seats correctly otherwise there is a danger of suction noises
32. Retainer
^ Secured to edge of brake booster
33. Heat shield
^ Application
Refer to Parts Supplier
34. Retainer
^ Used to secure the wiring harness
35. Sealing plug