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Removing and installing brake servo unit > < Summary of components of brake servo unit, master brake cylinder as of MY 2011

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Removing and installing master brake cylinder
Removing and installing master brake cylinder
Special tools and workshop equipment required
t  Hose clamp -MP7-602 (3094)-
t  Removal and installation pliers, e.g. -VAS 6340-
t  Vehicle diagnosis, measurement and information system -VAS-
t  Brake filling and bleeding device, e. g. -VAS 5234-
t  Extraction bottle (commercially available)
t  Repair kit -1H0 698 311 A-
t  Brake fluid → Chapter
  Note
t  The master brake cylinder must not be repaired.
t  Assignment → Electronic Catalogue of Original Parts.
Removing:
–  Remove engine cover → engine; Rep. gr.10.
–  Remove air filter → Engine; Rep. gr.24 (fuel engines) or → Engine; Rep. gr.23 (diesel engines).
–  Remove battery and battery tray → Electrical System; Rep. gr.27.
–  Lay sufficient non-fluffing cloths around the engine and gearbox.
   
–  Disconnect plug -1- from the brake fluid level warning contact -F34-.
For vehicles as of MY 2011
–  Disconnect plug from brake light switch -F- → Chapter.
Continued for all vehicles
–  Unclip vacuum hose -6- from the brake fluid reservoir.
–  After opening the breather screws on the front axle brake calipers pump off brake fluid by repeatedly pressing the brake pedal from the brake fluid reservoir.
–  Clamp off the running-on line of the clutch master cylinder -2- with hose clamp -MP7-602 (6340)-.
–  Open spring strap clamps of the running-on line of the clutch master cylinder -2- using assembly pliers.
–  Disconnect the running-on line of the clutch master cylinder -2- from the brake fluid reservoir -3- and tie up.
–  Unclip the brake lines from the holder -7-.
–  Unscrew the brake lines from the master brake cylinder -5- and shut off.
–  Shut-off the connections of the brake lines on the master brake cylinder with screw plugs from the repair kit SP No. 1 H0 698 311 A.
–  Release the nuts of the master brake cylinder -arrows-.
–  Carefully pull off the master brake cylinder -5- from the brake servo unit -4-.
Installing:
  Note
t  Install new gasket ring between the master brake cylinder and the brake servo unit.
t  When installing the master brake cylinder with the brake servo unit pay attention to the correct positioning of the pressure rod in the master brake cylinder.
t  Only fill up with new brake fluid.
Installation is carried out in the reverse order.
–  Fill up with new brake fluid.
–  Install the battery tray and battery → Electrical System; Rep. gr.27.
–  Connect battery → Electrical System; Rep. gr.27.
Vehicles without ABS and with ABS, ABS/TCS BOSCH 8.0
–  Bleeding brake system → Chapter.
Vehicles with ABS//TCS/ESP BOSCH 8.0
–  Perform basic setting of vehicle diagnosis, measurement and information system -VAS- → Chapter.
Continued for all vehicles
–  Bleed clutch → Gearbox; Rep. gr.30.
–  Install air filter → Engine; Rep. gr.24 (petrol engines) or → Engine; Rep. gr.23 (diesel engines).
–  Install engine cover → engine; Rep. gr.10.
–  Perform a vehicle system test with vehicle diagnosis, measurement and information system -VAS- → Chapter.
  S47-0118
Tightening torques:
Master brake cylinder to brake servo unit
t  Use new nuts!
20 Nm
Brake lines to master brake cylinder14 Nm

   

Removing and installing brake servo unit > < Summary of components of brake servo unit, master brake cylinder as of MY 2011