Hydraulic Unit, Brake Booster/Brake Master Cylinder Mark 60, Assembly Overview

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

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





1- Brake booster
^ For gasoline engines, the vacuum is taken from the intake manifold.
^ Diesel engines, have a vacuum pump to create the required vacuum.
^ With some vehicles, a brake system vacuum pump -V192- is installed.





^ Functional check
- With engine switched off, press 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).
^ If faulty, replace complete
^ Non-return valve (in vacuum hose)





2- Cap
3- Brake fluid reservoir
4- Sealing plug
^ Coat with brake fluid and press into brake master cylinder
5- Retainer pin
^ Insert through brake master cylinder
6- Brake master cylinder
^ Sender 1 for brake booster -G201- is installed on vehicles with ABS/EDL/ASR/ESP
^ Cannot be repaired. If faulty, replace complete.
7- Connection for brake line
^ Brake master cylinder/primary piston circuit 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- Connection for brake line
^ Master brake cylinder/secondary piston circuit to hydraulic unit
11- Control module
^ Do not separate connector before On Board Diagnostic (OBD)
12- ABS hydraulic unit
^ The ABS hydraulic pump -V64- and valve block must not be separated from one another
^ When changing the hydraulic unit, always seal the old part with the plugs from the repair kit Part No. 1H0 698 311A





13- Retainer
14- Cap nut, 20 Nm (15 ft. lb)
15- Bolts, 8 Nm (70 in lb)
16- Torx(R) head bolt E 5, 4 Nm (35 in lb)
17- Connection for brake line
^ Hydraulic unit to left rear wheel cylinder/caliper
18- Connection for brake line
^ Hydraulic unit to right rear wheel cylinder/caliper
19- Self-locking hex nut, 20 Nm (15 ft. lb)





20- Mounting plate
^ Used to secure the wiring harness
21- Heat shield
22- Brake pressure sender 1 -G201-
^ Installed only on vehicles with ABS/EDL/ASR/ESP





23- Sealing ring
^ Always replace
24- Sealing plug
^ Connection for vacuum hose
25- Gasket
^ For brake booster
26- Self-locking hex nut, 20 Nm (15 ft. lb)
27- Boot
^ Make sure it seats correctly, danger of suction noises

Connecting brake lines from tandem brake master cylinder to hydraulic unit





Fig. 1 Vehicles with ABS, ABS/EDL, ABS/EDL/ASR and ABS/EDL/ASR/ESP
A - Secondary piston circuit
B - Primary piston circuit
1- Hydraulic unit to left rear wheel cylinder/brake caliper
2- Hydraulic unit to right front brake caliper
3- Hydraulic unit to left front brake caliper
4- Hydraulic unit to right rear wheel cylinder/brake caliper