Sprinter 2500 L5-2.7L DSL Turbo (2003)
Vacuum Brake Booster: Service and Repair
POWER BRAKE BOOSTER
REMOVAL
1. Using a suction gun remove as much brake fluid from the reservoir as possible.
2. Disconnect the brake level switch electrical connector.
3. Remove the brake lines from the master cylinder Seal of ~ the ends and bore holes with plugs.
4. Remove the master cylinder from the booster.
5. Remove the booster vacuum hose and check valve (Fig. 23).
6. Remove the pedal push rod clip (Fig. 23).
7. Remove the booster mounting nuts (Fig. 23).
8. Remove the booster from the vehicle.
INSTALLATION
1. Install the brake booster to the vehicle.
2. Install the booster mounting nuts (Fig. 23). Tighten to 25 Nm (221 inch lbs.).
3. Install the push rod pin & clip (Fig. 23).
4. Install the brake booster vacuum line and check valve (Fig. 23).
5. Install the master cylinder to the brake booster. Tighten to 28 Nm (248 inch lbs.).
6. Install the brake lines to the master cylinder. Tighten to 14 Nm (124 inch lbs.).
7. Install the brake level switch electrical connector.
8. Bleed the base brake system.