Brake Booster/Brake Master Cylinder, Assembly Overview (Vehicles As of Model Year 2002)

Brake booster/brake master cylinder, assembly overview (Vehicles as of model year 2002)

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 - Trunnion bolt, 10 Nm

5 - Brake fluid reservoir

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.
^ Vehicles with a gasoline engine and automatic transmission are equipped with a vacuum pump for brakes.
^ 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.
^ With adhesive seal

10 - Seal ring
^ Always replace

11 - Brake line, 24 Nm
^ Brake master cylinder/primary piston circuit to hydraulic unit

12 - Brake line, 24 Nm
^ Brake master cylinder/secondary piston circuit to hydraulic unit

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

14 - Bulkhead





Adjusting ball plunger
Left-hand drive vehicles:
a - 159 mm 0.5 mm

Note:
^ Surface - 1 - for measuring
^ 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.

Tightening torque: