Brake Booster/Brake Master Cylinder, Assembly Overview (Vehicles As of Model Year 2000)

Brake booster/brake master cylinder, assembly overview (Vehicles as of model year 2000)

Note: Use only new brake fluid. Observe information on brake fluid reservoir!





1 - T 45 torx socket head bolt, 25 Nm

2 - Self-locking hex nut, 49 Nm

3 - Sealing plug
^ Moisten with brake fluid and press into brake fluid reservoir

4 - Brake fluid reservoir

5 - Seal ring

6 - Cap

7 - Supply hose
^ From brake fluid reservoir to clutch master cylinder

8 - Vacuum hose
^ Insert into brake booster unit

9 - Tandem brake booster
^ Adjusting ball plunger
^ On gasoline engines the vacuum required is taken from the intake manifold.
^ As of model year 2001, vehicles with a gasoline engine and automatic transmission are equipped with a brake vacuum pump Brake system vacuum pump V192.
^ To produce vacuum with diesel engines, a vacuum pump is equipped.
^ Functional check:
- With engine switched off, 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 booster unit is working properly, the pedal will be felt to give slightly under foot (booster assist becomes effective).
- If faulty, replace completely.

10 - Gasket

11 - Bulkhead

12 - Seal ring
^ Always replace

13 - Brake line
^ Brake master cylinder/primary piston circuit to hydraulic unit

14 - Brake line
^ Brake master cylinder/secondary piston circuit to hydraulic unit

15 - Hex bolt

16 - Tandem master cylinder
^ Cannot be repaired. If faulty, replace completely.





Adjusting ball plunger
a - 159 mm 0.5 mm

Note:
^ When measuring the ball plunger, it must be set at right angles to the surface of the brake booster.
^ Measure to end of ball plunger without gasket installed.