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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Mercedes-Benz G-Class (W463, 1999 issue)

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Mercedes-Benz G-class
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Mercedes-Benz
G-class
Introduction
Controls and operation receptions
Current care and maintenance
Engine
System of cooling, heating, ventilation and air conditioning
The power supply system and exhaust
Systems of an electric motor
Automatic Transmission
Transmission Line
Brakes and auxiliary systems
Specifications
Check the brake system for leaks
Check of serviceability of functioning of the vacuum brake booster
Removal and installation of the brake fluid reservoir and the master cylinder (GTZ)
Removing and installing brake servo stroke sensor diaphragm BAS
Removal and installation of the vacuum pump (diesel engines)
Removing and installing control modules ABS / EBV / ESP
Removing and installing hydromodulator ABS / 4-ETS
Removal and installation of wheel gauges ABS
Removal and installation of the rotor wheel ABS sensors
Removing and installing brake pedal
Removal and installation of the cocking lever parking brake with bearing bracket
Replacement brake hoses
Check and replacement of brake pads
Replacing the parking brake shoes
Removing and installing brake caliper
Repair of fixed-type caliper
Check, removal and installation of brake disks
Removal and installation of components of the cable handbrake
Adjusting the parking brake
Bleeding brake system
Suspension and steering
Body
Onboard electric
Wiring
 


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Removing and installing brake servo stroke sensor diaphragm BAS



Assembling the vacuum amplifier

Details of the installation of the brake booster (1 of 4)

8 - Connector wiring brake fluid level
9 - a brake fluid reservoir
10 - Brake line

11 - GTZ
12 - Vacuum line
A7 / 7 - Brake booster

Details of the installation of the brake booster (2 of 4)

1 - Cover the left under the dashboard
3 - Fixing bolt
4 - Split pin

13 - Nuts
S9 / 1 - The gauge-switch of stoplights

Details of the installation of the brake booster (3 of 4)

14 - The pressure bolt
16b - Retaining Ring
A7 / 7x1 - Connector wiring distance sensor diaphragm BAS

A7 / 7x2 - wiring connector of the solenoid valve / gauge-switch is released, BAS
A7 / 7b1 - BAS diaphragm travel sensor

Details of the installation of the brake booster (4 of 4)

3 - Fixing bolt

C - Control Unit

PERFORMANCE ORDER

  1. Disconnect the connector (8) electrical brake fluid level in the reservoir (9) brake fluid.
  2. Disconnect from the GTZ (11) brake line (10).
  3. Disconnect the connector (A7 / 7x2) electrical solenoid valve / gauge-switch is released, BAS, and the connector (A7 / 7x1) stroke sensor diaphragm BAS.
  4. To expand the space loosen the clamping screw (14) ground terminal starting the engine from an external power source.
  5. Throwing a vacuum by a few push-pedal brakes, disconnect the brake booster (A7 / 7) vacuum line (12), - evaluate the state of the rubber plug fixing lines, in case of need make replacement.
  6. To expand the space, remove the control unit (C) and move it to the side without disconnecting any lines of communication.
  7. Remove the cover (1) to the left under the dashboard.
  8. Turning to the left, pull and remove the gauge-switch of stoplights (S9 / 1).
  9. Remove the cotter pin (4) and remove the bolt (3) securing the pushrod to the brake pedal. Assess the bolt, if necessary, prepare a removable element - pin must be replaced without fail.
  10. Give nuts (13), - the whole self-locking fasteners be replaced without fail.
  11. Remove the brake booster (A7 / 7), complete with the GTZ (11).
  12. Installation is in the reverse order - the seat surface of the assembly prior to installation with sealant.
  13. In summary pump over brake system (see. Section Bleeding brake system), inspect the hydraulic path for signs of leaks and make check of serviceability of functioning of brake lights.

BAS diaphragm travel sensor

PERFORMANCE ORDER

  1. Details of the sensor diaphragm stroke BAS shown in the illustration details the installation of the brake booster (3 of 4)
  2. A few taps on the brake pedal reset the residual vacuum in the brake pressure for the purpose of releasing the sealing ring sensor.

If the O-ring will be drawn into the amplifier assembly, the sensor must be replaced.

  1. To expand the space loosen the clamping screw (14) ground terminal starting the engine from an external power source.
  2. Disconnect the connector (A7 / 7x1).
  3. Having hooked a suitable tool, remove the retaining ring (16b), - the ring is subject to replacement without fail.
  4. Pull, pull the sensor (A7 / 7b1) from its landing slot.
  5. Installation is in the reverse order - track correctness of landing of a sealing and locking rings. Before filling the sensor O-ring soak it in front of a soap solution.
  6. Start the engine several times depress the foot brake, then again turn the ignition off and check for signs of air suction through the sensor.




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Removal and installation of the brake fluid reservoir and the master cylinder (GTZ)
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Removal and installation of the vacuum pump (diesel engines)

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