B3FG1SK1 - 607

REMOVAL - REFITTING BRAKE SERVO

1 - FOREWORD

Assembling the brake amplifier on its bracket is by using a collar type clip (1) .

IMPERATIVE : this assembly operation requires a great deal of care .

IMPERATIVE : scrupulously follow the method described .

IMPERATIVE : systematically replace the catch (1) and the clips (7) .

2 - SPECIAL TOOLS

[1] tightening sleeve (-).0813 .

3 - REMOVAL

REMOVE THE MASTER CYLINDER .

Disconnect the vacuum pipe (2) .

Disconnect and move aside the accelerator cable (3) .

Open the fuse box cover (4) .

Remove the bolts (5) .

Remove the cover under the instrument panel (6) .

Remove the clip (7) .

Make a vertical mark on the brake amplifer and on the cable (8) .

Unclip the brake pipe (9) .

Using the tool [1], unscrew the nut of the (1) clip until it reaches peening point (A) .

Move aside the clip .

RIGHT HAND DRIVE

Remove the brake amplifier from its bracket in order to access the fastener (10) .

Remove the clip (10) .

ALL MODELS

Remove the brake servo unit .

Remove the collar (1) .

WARNING : take care not to damage the brake pipes .

Remove the bolts (11) in the event of the brake amplifier being replaced .

Remove the plate (12) .

4 - REFITTING

Position a new clip (1) on its bracket .

NOTE : the new clips are supplied open so that they can be easily refitted .

IMPERATIVE : always replace the brake amplifier securing clip (1) .

WARNING : the clip must not overlap the edges (B) of the bracket .

WARNING : correctly position the clip on the lower bracket at (C) .

Make a mark on the new brake amplifier which lines up with the mark on the old brake amplifier .

When refitting the plate (12) on the brake amplifier, line up the mark with the fastener (13), so that the studs securing the master cylinder are in the correct position .

Tightening torques :

RIGHT HAND DRIVE

Line up the brake amplifier .

Put a new fastener (10) in place .

ALL MODELS

NOTE : on the brake amplifier and the cable (8) align the marks which were made at the time of disassembly .

Fit : The brake servo unit .

IMPERATIVE : check that the position of the fastener (13) in the centralising pin (14) is correct .

WARNING : seat the brake amplifier on the bracket, making sure that the clip (1) is correctly overlapping the bracket (15) and the plate (12) .

NOTE : if the resistance is less than (1) .

Tighten the clip (1) gradually by hand using the tool [1], ensuring periodically that it is correctly positioned, by rotating it and checking manually that the clip correctly overlaps the bracket (15) and the plate (12) .

Tighten the bolt in the clip (1) to 2 dan.m .

WARNING : check again that the clip is in the correct position around the edge and pull hard at several points on the brake amplifier to ensure that it is correctly fastened .

Continue the fitting operations in the reverse order to removal .

IMPERATIVE : always renew : the clip (7) .

ADJUST THE STOP LAMP SWITCH .

Fit : MASTER CYLINDER .

FILL AND BLEED THE BRAKE CIRCUIT .

DYNAMIC STABILITY CONTROL

Bleed the esp pre-charge pump hydraulic system using the diagnostic equipment DIAG 2000 .

ALL MODELS

IMPERATIVE : with the engine running, press very hard on the brake pedal to ensure the reliability of the assembly .