Brakes and Traction Control: Service and Repair
WM 461019 Removing and installing mounting saddle
Preliminary work
1. Jack up the vehicle.
2. Remove the two A-pillar trim panels.
3. Extend the electrically adjustable steering column fully in center position and do not engage the steering lock. Disconnect the battery.
4. Remove dashboard.
5. Remove relay carrier (under dashboard).
6. Remove the two control units -Arrow- on the right side under the dashboard.
7. Release the holder (relay carrier/Kessy control unit/immobilizer/vehicle electrical system control unit) engaged on the left side and front (screwed on the right side).
8. Release foot-operated parking brake from the dashboard carrier only and let it hang. Do not remove the lower A-pillar trim panel.
9. Mark steering column on the lower sliding piece!
10. Remove steering column from the dashboard bracket and carefully put it to one side.
Steering column
11. Remove dashboard bracket.
12. Separate the steering column from the lower sliding piece with a quick strong pull.
13. Remove cowl panel.
14. Remove engine-compartment trim panel on the left.
15. Partly remove E-box and lay it aside.
16. Remove bulkhead from plenum panel on the left by unscrewing the three screws.
17. Remove underbody protection.
General warning notes
Caution:
Increased risk when handling airbag modules.
Injury and material damage may occur if airbag units are not handled correctly.
- Observe safety regulations for handling airbag modules.
Technical values
Tightening torques for brake mechanics.
Tightening torques for brake hydraulics.
Tightening torques for steering.
Removing
All fastening screws in the mounting saddle can be accessed from the engine compartment. When completing this step, it is a good idea to first remove the mounting saddle fastening screw that is accessible from underneath (only remove the other three screws just before you remove the mounting saddle!).
Mounting saddle attachment points: three in plenum panel, one outside next to the steering column.
1. 1. Remove mounting saddle screw - outside of plenum panel.
2. Remove accelerator pedal module.
3. Remove the master cylinder on manual transmission vehicles.
4. Unclip brake pedal from brake booster.
-1- - Pedal module (removed) with unlocking tool T10189 for brake pedal in position.
- Position the unlocking tool T10189 so that it is located in the right mould of the support and is perpendicular to the vehicle floor. Here the deflection point of force (bending in the unlocking tool T10189) is right next to the screw head -Arrow-.
- When pressing forward on the lever (unlocking tool) (in direction of travel!), the brake pedal mounting is pressed apart and the ball of the push rod is released. At the same time, pull the brake pedal to the rear (against the direction of travel!) and release the brake pedal from the push rod.
Releasing push rod from brake pedal
5. Remove bracket (support) from crash support on mounting saddle -Arrows-.
Removing bracket
6. Remove the dust boot from the push rod and then remove the four nuts on the brake booster -Arrows-.
Nuts on brake booster
7. Unclip cable duct cover from main wire harness against the direction of travel -Arrow- and cut the tie-wraps (three in cable duct and three on the left of the cable duct). Mounting saddle is removed together with the cable duct!
Opening cable duct
8. Remove mount from mounting saddle in plenum panel and carefully remove the mounting saddle.
Installing
1. Re-fit the mounting saddle.
2. Secure cable duct on new mounting saddle and pre-fit the tie-wraps!
3. Tilt mounting saddle against the direction of travel and fit it underneath first, then guide the mounting saddle into position. Check that the cables are routed correctly (cable duct).
Fitting mounting saddle
4. Fit the mounting saddle (all four attachment points!).
5. Fit the brake booster. Then pull the dust boot over the push rod. Ensure it is seated correctly!
6. Fit bracket (support) on crash support on the mounting saddle.
7. Secure main wire harness in the cable duct using the tie-wraps and then clip on the cable duct cover.
Main wire harness in cable duct
8. Secure main wire harness on cable duct.
Main wire harness at the side of the cable duct
Subsequent work
1. Guide steering column into the separating piece with a quick strong jerk (in line with the mark you made!). Then carefully lay it aside.
2. Fit dashboard bracket. Check that the foot-operated parking brake and cables are routed correctly. Fit parking brake grille.
3. Fit dashboard bracket.
4. Fit the two struts for the crash support (bracket support).
Support
5. Fit steering column to bracket.
6. Fit the master cylinder on manual transmission vehicles.
7. Fit frame for relay carrier.
8. Fit relay carrier.
9. Fit control units in relay carrier frame.
10. Position fuse carrier at right and left (align dashboard before tightening the screw).
11. Fit the dashboard.
12. Clip push rod into the brake pedal by pressing the pedal onto the push rod until it clicks into place.
13. Fit accelerator pedal module.
14. Fit dashboard trim panels.
15. Fit A-pillar trim panel.
16. Install accelerator pedal module.
17. Fit separator plate on plenum panel.
18. Fit E-box.
19. Fit engine-compartment cover.
20. Fit cowl panel.
21. Fit underbody protection.
22. Connect the battery and carry out the work required after disconnecting the battery.
23. Read out fault memory.