Mark 60 Hydraulic Unit, Brake Booster/Brake Master Cylinder, Assembly Overview, Vehicles From 10.00

Note:
^ The complete master cylinder and brake booster can be replaced independently of each other.

Mark 60 Hydraulic unit, Brake booster/Brake master cylinder, assembly overview, Vehicles from 10.00:

1 - Brake booster, left-hand drive
^ On gasoline engines the vacuum required is taken from the intake manifold.
^ In vehicles with a gasoline engine and an automatic transmission, the Brake System Vacuum Pump V192 is installed.
^ On Diesel engines a vacuum pump is installed to create the required vacuum.
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).
^ If faulty, replace complete
^ Check valve (in vacuum hose)
- Functional check
^ Brake assist in brake booster

2 - Sealing cap
3 - Brake fluid reservoir, left-hand drive (LHD)
4 - Sealing plugs
^ Moisten with brake fluid and press in the 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, 14 Nm
^ Brake master cylinder (primary circuit) to hydraulic unit

8 - Brake line, 14 Nm
^ Hydraulic unit to left front brake caliper

9 - Brake line, 14 Nm
^ Hydraulic unit to right front brake caliper

10 - Brake line, 14 Nm
^ Brake master cylinder (secondary circuit) to hydraulic unit

11 - ABS control module J104
^ Do not disconnect connector before performing On Board Diagnosis (OBD)

12 - ABS hydraulic unit N55

The hydraulic unit consists of the following components:
^ ABS hydraulic pump V64
^ Valve block (contains the inlet-exhaust valves)

13 - Bracket
14 - Hex nut, 20 Nm
15 - Bolts, 8 Nm
16 - Torx(R) socket head bolt E5, 4 Nm
^ Always use new bolts

17 - Brake line, 14 Nm
^ Hydraulic unit to left rear wheel cylinder/brake caliper

18 - Brake line, 14 Nm
^ Hydraulic unit to right rear wheel cylinder/brake caliper

19 - Brake fluid reservoir, right-hand drive
20 - Sealing plugs
^ Moisten with brake fluid and install into brake fluid reservoir

21 - Breather valve
22 - Retaining plate,
^ Used to secure the wiring harness

23 - Self-locking hex nut, 20 Nm
24 - Brake master cylinder, right-hand drive (RHD)
^ Must not be repaired. If faulty, replace complete.

25 - Brake pressure sensor 1 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
31 - Boots
^ Make sure boot seats correctly otherwise there is a danger of suction noises

32 - Retainer
^ Secured to edge of brake booster

33 - Heat shield
34 - Retainer
^ Used to secure the wiring harness

35 - Sealing plugs