Brake servo/brake pump assembly - r r
- Make
- Alfa Romeo
- Model
- GT Factory Service Manual
- Year
- 2003–2010
- Section
- Hydraulic braking system › Brake servo/brake pump assembly - r r
BRAKE SERVO/BRAKE PUMP ASSEMBLY - R R
Removing
Position the vehicle on a lift.
Proceed with the removal
Proceed with the removal
Op. 5530B52 BATTERY DRIP TRAY/SUPPORT - R.R..
Proceed with the removal
Op. 3340A12 ABS HYDRAULIC AND ELECTRONIC CONTROL UNIT.
Proceed with the removal
Op. 3340A13 ABS CENTRAL MOUNT - R R.
1. Undo the bolt (1a) and remove the brake/clutch fluid reservoir (1b).
2. Disconnect the single-acting valve from the brake servo.
1. Work on the fastening clips (1a) and release the brake pump (1b) from the pedal.
Take care not to damage the fastening clips.
2. Undo the nuts fixing the brake servo/brake pump assembly to the pedals mounting.
Proceed with the removal
Op. 4450B02 LEFT FRONT WHEEL R R.
Proceed with the removal
Op. 7055B65 ENGINGE BAY DUSTGUARD PROTECTION IN LEFT FRONT WHEEL ARCH R R.
Proceed with the removal
Op. 7055B90 LEFT FRONT WHEEL ARCH LINER - R.R..
Proceed with the removal
Op. 7055B54 UNDER-ENGINE GUARD - R R.
Position a hydraulic jack beneath the gearbox.
1. Unscrew the bolt securing the power unit rigid mount to the flexible block.
Lower the power unit as necessary using the hydraulic jack.
Working underneath the vehicle, extract the brake servo/brake pump assembly from its housing.
Tighten the bolt securing the gearbox side power unit rigid support to the flexible mounting.
Remove the hydraulic jack from beneath the gearbox
1. Working in the engine compartment, remove the brake servo/brake pump assembly.
Refitting
Working in the engine compartment, temporarily position the brake servo/brake pump assembly.
Position a hydraulic jack beneath the gearbox.
Unscrew the bolt securing the power unit rigid mount to the flexible block.
Working underneath the vehicle, place the brake servo/brake pump assembly in position.
1. Tighten the bolt securing the power unit gearbox side rigid support to the flexible mounting to the recommended torque.
| Fastening | Component | Ø | Value (daNm) | |
|---|---|---|---|---|
| 1 |
Remove the hydraulic jack from beneath the gearbox
Proceed with the refitting
Op. 7055B54 UNDER-ENGINE GUARD - R R.
Proceed with the refitting
Op. 7055B90 LEFT FRONT WHEEL ARCH LINER - R.R..
Proceed with the refitting
Op. 7055B65 ENGINGE BAY DUSTGUARD PROTECTION IN LEFT FRONT WHEEL ARCH R R.
Proceed with the refitting
Op. 4450B02 LEFT FRONT WHEEL R R.
1. Working in the passenger compartment, tighten the nuts fixing the brake servo/brake pump assembly to the pedals mounting.
| Fastening | Component | Ø | Value (daNm) | |
|---|---|---|---|---|
| 1 | Nut | BRAKE SERVO | M8 | 1.8 ÷ 2.6 |
2. Connect the brake pump to the pedal.
Connect the single-acting valve to the brake servo.
Place the brake-clutch fluid reservoir in its housing and secure it using the bolt.
Proceed with the refitting
Op. 3340A13 ABS CENTRAL MOUNT - R R.
Proceed with the refitting
Op. 3340A12 ABS HYDRAULIC AND ELECTRONIC CONTROL UNIT.
Proceed with the refitting
Op. 5530B52 BATTERY DRIP TRAY/SUPPORT - R.R..
Proceed with the refitting
Proceed with the refitting
Op. 0010T64 BRAKE AND OR CLUTCH FLUID CHECK LEVEL AND TOP UP AS NECESSARY.
Proceed with the refitting
Op. 0010T65 HYDRAULIC BRAKE SYSTEM BLEED AIR.
Remove the vehicle from the lift.
Removing
Position the vehicle on a lift.
Proceed with the removal
Proceed with the removal
Op. 5530B52 BATTERY DRIP TRAY/SUPPORT - R.R..
Proceed with the removal
Op. 4450B02 LEFT FRONT WHEEL R R.
Proceed with the removal
Op. 3330C30 BRAKE FLUID RESERVOIR - R + R AND WASH INSIDE.
Proceed with the removal
Op. 3340A12 ABS HYDRAULIC AND ELECTRONIC CONTROL UNIT.
Proceed with the removal
Op. 3340A13 ABS CENTRAL MOUNT - R R.
1. Disconnect the single-acting valve from the brake servo.
2. Release the rigid pipe from the A.B.S. hydraulic control unit to the right front brake (2a) from the fastening band (2b).
Working in the passenger compartment, release the buttons and move the trim.
1. Work on the fastening clips (1a) and release the brake pump (1b) from the pedal.
Take care not to damage the fastening clips.
1. Undo the nuts fixing the brake servo/brake pump assembly to the pedals mounting.
1. Working in the engine compartment, remove the brake servo/brake pump assembly.
Refitting
Working in the engine compartment, place the brake servo/brake pump assembly in position.
1. Working in the passenger compartment, tighten the nuts fixing the brake servo/brake pump assembly to the pedals mounting.
| Fastening | Component | Ø | Value (daNm) | |
|---|---|---|---|---|
| 1 | Nut | BRAKE SERVO | M8 | 1.8 ÷ 2.6 |
Connect the brake pump to the pedal.
Fit the trim in position and secure it using the buttons.
Fasten the rigid pipe from the A.B.S. hydraulic control unit to the right front brake to the band.
Connect the single-acting valve to the brake servo.
Proceed with the refitting
Op. 3340A13 ABS CENTRAL MOUNT - R R.
Proceed with the refitting
Op. 3340A12 ABS HYDRAULIC AND ELECTRONIC CONTROL UNIT.
Proceed with the refitting
Op. 3330C30 BRAKE FLUID RESERVOIR - R + R AND WASH INSIDE.
Proceed with the refitting
Op. 5530B52 BATTERY DRIP TRAY/SUPPORT - R.R..
Proceed with the refitting
Top up the brake-clutch fluid level
Op. 0010T64 BRAKE AND OR CLUTCH FLUID CHECK LEVEL AND TOP UP AS NECESSARY.
Bleed the air from the hydraulic braking system
Op. 0010T65 HYDRAULIC BRAKE SYSTEM BLEED AIR.
Proceed with the refitting
Op. 4450B02 LEFT FRONT WHEEL R R.
Remove the vehicle from the lift.
Removing
Proceed with the removal
During the removal of the battery, take care to also disconnect the starter motor supply lead, shown in the diagram, from the maxi fuse box.
Proceed with the removal
Op. 3330C30 BRAKE FLUID RESERVOIR - R + R AND WASH INSIDE.
Proceed with draining the braking system using the bleed valve on the brake caliper rather than drawing off the fluid from the reservoir using a syringe.
1. Disconnect the electrical connection from the ABS electronic and hydraulic control unit.
| Description | Connector | |
|---|---|---|
| 1 | ABS control unit | See M50 ABS CONTROL UNIT ( FRONT ) |
2. Undo the connectors (2a) and (2b) and remove the rigid pipes from the master cylinder to the A.B.S. hydraulic control unit (2c).
3. Undo the connectors (3a) and disconnect the rigid pipes from the hydraulic control unit to the brake calipers (3b), hydraulic control unit side.
4. Release the A.B.S. system pipes from the fastenings.
1. Remove the clips (1a) and remove the ABS electronic and hydraulic control unit (1b).
1. Undo the bolts (1a) and remove the A.B.S. control unit support (1b) after having released the clutch system pipe from the band (1c).
Working in the passenger compartment, release the buttons and move the trim.
1. Work on the fastening clips (1a) and release the brake pump (1b) from the pedal.
Take care not to damage the fastening clips.
1. Undo the nuts fixing the brake servo/brake pump assembly to the pedals mounting.
1. Disconnect the vacuum pipe complete with single-acting valve from the brake servo.
2. Release and remove the brake servo/brake pump assembly
Refitting
Working in the engine compartment, place the brake servo/brake pump assembly in position.
Connect the vacuum pipe complete with single-acting valve to the brake servo.
1. Working in the passenger compartment, tighten the nuts fixing the brake servo/brake pump assembly to the pedals mounting to the recommended torque.
| Fastening | Component | Ø | Value (daNm) | |
|---|---|---|---|---|
| 1 | Nut | BRAKE SERVO | M8 | 2.1 ÷ 2.9 |
Connect the brake pump to the pedal.
Fit the trim in position and secure it using the buttons.
Fasten the clutch system pipe to the band, then place the A.B.S. control unit support in position and secure it using the bolts.
Place the A.B.S. hydraulic and electronic control unit in position and secure it using the clips.
Secure the A.B.S. system pipes to the fastenings.
1. Connect the rigid pipes from the hydraulic control unit to the brake calipers (1a), hydraulic control unit side and tighten the connectors (1b) to the recommended torque.
| Fastening | Component | Ø | Value (daNm) | |
|---|---|---|---|---|
| 1b | Connector | PIPE CENTRAL RIGID BRAKING PIPE/REAR BRAKES | M10/M12 | (ABS control unit side) 1.3 - 1.5 |
2. Place the rigid pipes from the master cylinder to the A.B.S. hydraulic control unit (2a) in their housings and tighten the connectors (2b) and (2c) to the recommended torque.
| Fastening | Component | Ø | Value (daNm) | |
|---|---|---|---|---|
| 2b | Connector | PIPE FROM PUMP TO HYDRAULIC CONTROL UNIT | M12 | (Master cylinder side) 1.3 - 1.5 |
| Fastening | Component | Ø | Value (daNm) | |
|---|---|---|---|---|
| 2c | Connector | PIPE FROM PUMP TO HYDRAULIC CONTROL UNIT | M12 | (ABS control unit side) 1.3 - 1.5 |
3. Connect the electrical connection to the ABS electronic and hydraulic control unit.
Proceed with the refitting
Op. 3330C30 BRAKE FLUID RESERVOIR - R + R AND WASH INSIDE.
Proceed with the refitting
Bleed the air from the hydraulic braking system
Op. 0010T65 HYDRAULIC BRAKE SYSTEM BLEED AIR.
Removing
Position the vehicle on a lift.
Proceed with the removal
5530B10 BATTERIA - S.R.
Proceed with the removal
5530B52 SUPPORTO/CESTELLO batteria - S.R.
Proceed with the removal
3340A12 CENTRALINA idraulica ed elettronica dell''impianto A.B.S. - S.R.
Proceed with the removal
Op. 3340A13 ABS CENTRAL MOUNT - R R.
1. Undo the connectors (1a) and remove the rigid pipes from the master cylinder to the A.B.S. hydraulic control unit (1b).
2. Disconnect the electrical connection from the brake-clutch fluid minimum level warning light switch.
| Description | Connector | |
|---|---|---|
| 2 | Brake fluid level sensor (switch) | K25 |
3. Undo the bolt (3a) and move the brake/clutch fluid reservoir (3b) aside.
1. Disconnect the single-acting valve from the brake servo.
2. Release the rigid pipe from the A.B.S. hydraulic control unit to the right front brake (2a) from the fastening band (2b).
Working in the passenger compartment, release the buttons and move the trim.
1. Work on the fastening clips (1a) and release the brake pump (1b) from the pedal.
Take care not to damage the fastening clips.
1. Undo the nuts fixing the brake servo/brake pump assembly to the pedals mounting.
1. Working in the engine compartment, remove the brake servo/brake pump assembly.
Refitting
Working in the engine compartment, place the brake servo/brake pump assembly in position.
1. Working in the passenger compartment, tighten the nuts fixing the brake servo/brake pump assembly to the pedals mounting.
| Fastening | Component | Ø | Value (daNm) | |
|---|---|---|---|---|
| 1 | Nut | BRAKE SERVO | M8 | 2.2 |
Connect the brake pump to the pedal.
Fit the trim in position and secure it using the buttons.
Fasten the rigid pipe from the A.B.S. hydraulic control unit to the right front brake to the band.
Connect the single-acting valve to the brake servo.
1. Place the brake-clutch fluid reservoir (1a) in its housing and secure it using the bolt (1b).
2. Connect the electrical connection to the brake-clutch fluid minimum level warning light switch.
3. Place the rigid pipes from the master cylinder to the A.B.S. hydraulic control unit (3a) in their housings and tighten the connectors (3b), master cylinder side to the recommended torque.
| Fastening | Component | Ø | Value (daNm) | |
|---|---|---|---|---|
| 3b | Connector | PIPE FROM PUMP TO HYDRAULIC CONTROL UNIT | M12 | (Master cylinder side) 1.3 - 1.5 |
Proceed with the refitting
Op. 3340A13 ABS CENTRAL MOUNT - R R.
Proceed with the refitting
3340A12 CENTRALINA idraulica ed elettronica dell''impianto A.B.S. - S.R.
Proceed with the refitting
5530B52 SUPPORTO/CESTELLO batteria - S.R.
Proceed with the refitting
5530B10 BATTERIA - S.R.
Bleed the air from the hydraulic braking system
Op. 0010T65 HYDRAULIC BRAKE SYSTEM BLEED AIR.
Remove the vehicle from the lift.
Parts & tools for this job For 2003 Alfa Romeo GT
- PARTBrake padsSearch: Alfa Romeo GT 2003 brake pads
- TOOLBrake bleeder kitSearch: one man brake bleeder kit
- FLUIDBrake fluidSearch: brake fluid
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