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Brake Servo, Replace (LHD)
 Remove
| 1. |
Detach cover of brake fluid reservoir
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| 2. |
Siphon out as much brake fluid as possible with siphon
bottle
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| 3. |
Remove battery
| • |
Detach earth connection from earth terminal
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| • |
Detach positive connection from battery
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| • |
If present: detach thermal protection
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| 4. |
Remove battery support
| • |
For diesel engines: Detach preheater system control unit
(4)
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| • |
Detach wiring harness plug (3)
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| • |
Detach wiring harness
| – |
Disconnect 2x cable ties (1)
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| 5. |
Detach coolant compensation tank
Note: Cooling system
remains sealed
| • |
Disconnect wiring harness plug
| – |
Set coolant compensation tank aside
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| 6. |
Unclip wiring harness from brake fluid reservoir
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| 7. |
Disconnect wiring harness plug from brake fluid level
sensor
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| 8. |
Remove hydraulic modulator
| • |
Disconnect hydraulic modulator wiring harness plug
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| • |
Detach 6x hydraulic line (1, 2 and 4)
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| 9. |
Detach hydraulic modulator bracket
| • |
Remove hydraulic modulator bracket
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| 10. |
For vehicles with manual transmission: detach supply line (1)
for clutch master cylinder from brake fluid reservoir
Note: Collect brake
fluid and seal apertures.
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| 11. |
Detach brake line from brake master cylinder
| • |
Unscrew 2x union bolt (3)
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| 12. |
Detach brake master cylinder from brake servo
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| 13. |
Detach vacuum line from brake servo
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| 14. |
Remove driver's side footwell panelling
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| 15. |
Detach piston rod for brake servo (1) from brake pedal
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Remove pedal bolt from brake pedal (2)
| – |
Detach retaining spring
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| 16. |
Detach brake servo from bulkhead
| • |
Unscrew 2x nut (arrows)
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| 17. |
For Z 17 DTL and Z 17 DTH: detach fuel filter with crash box 
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| 18. |
For Z 13 DTH: Detach charge air pipe with throttle valve
fitting
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| 19. |
Remove brake servo (2)
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Install
| 21. |
Attach brake servo to bulkhead
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| 22. |
For Z 17 DTL and Z 17 DTH: attach fuel filter with crash box
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| 23. |
For Z 13 DTH: attach charge air pipe with throttle valve
fitting
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| 24. |
Install pedal bolt for brake pedal
| • |
Attach retaining spring
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| 25. |
Install driver's side footwell panelling
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| 26. |
Attach vacuum line to brake servo
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| 27. |
Attach brake master cylinder to brake servo
| • |
Tighten 2x nut
- except for Z 19 DT, Z 19 DTJ, Z 19 DTL, Z 19 DTH (120 HP), Z 19
DTH 15 Nm
- Z 19 DT, Z 19 DTJ, Z 19 DTL, Z 19 DTH (120 HP), Z 19 DTH and as
of model year 2007: 21 Nm
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| 28. |
Attach brake line to brake master cylinder
| • |
Tighten 2x retaining bolt 14 Nm
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| 29. |
For vehicles with manual transmission: Attach supply line for
clutch master cylinder to brake fluid reservoir.
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| 30. |
Connect wiring harness plug to brake fluid level sensor
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| 31. |
Clip wiring harness on at brake fluid reservoir
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| 32. |
Attach hydraulic modulator bracket
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Insert hydraulic modulator bracket
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| 33. |
Install hydraulic modulator
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Attach 6x hydraulic line
| – |
Tighten 6x retaining bolt 14 Nm
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| • |
Connect hydraulic modulator wiring harness plug
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| 34. |
Attach coolant compensation tank to mounting
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Connect wiring harness plug for coolant level sensor
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| 35. |
Install battery support 15 Nm
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For diesel engines: Attach preheater system control unit
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| • |
Attach wiring harness plug
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| 36. |
Install battery
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Install battery bracket
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| • |
If present: install thermal protection
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| • |
Attach positive connection to positive terminal
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| • |
Attach earth connection to earth terminal
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| 38. |
Top up brake fluid reservoir to "MAX" marking
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| 39. |
Screw cover on to brake fluid reservoir
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| 40. |
Program volatile memories
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