Brakes and Traction Control: Service and Repair
WM 461019 Removing and installing mounting saddle
Tools
Preliminary work
1. Jack up the vehicle. -> 4000V0 Lifting the vehicle
2. Remove the two A-pillar trim panels. -> 705719 Removing and installing A-pillar trim 705719 Removing and installing A-pillar trim
3. Extend the electrically adjustable steering column fully in centre position and do not engage the steering lock. Disconnect the battery. -> 9000IN Work instructions after disconnecting the battery - section on "Disconnecting"
4. Remove dashboard. -> 701819 Removing and installing the instrument panel 701819 Removing and installing instrument panel
5. Remove relay carrier (under dashboard). -> 9790IN Relay carrier 9790IN Relay carrier
6. Remove the two control units -Arrow- on the right side under the dashboard -> 966619 Removing and installing Kessy/immobiliser control unit - section on "Removing" 966619 Removing and installing Kessy/immobiliser control unit, -> 971019 Removing and installing vehicle electrical system control unit - section on "Removing" Service and Repair.
7. Release the holder (relay carrier/Kessy control unit/immobiliser/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. -> 466019 Removing and installing pedal for foot-operated parking brake Service and Repair
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. -> 701219 Removing and installing dashboard bracket 701219 Removing and installing bracket for dashboard
12. Separate the steering column from the lower sliding piece with a quick strong pull. -> 481519 Removing and installing steering column 48151950 Removing and Installing Steering Column
13. Remove cowl panel. -> 664419 Removing and installing cowl panel cover Service and Repair
14. Remove engine-compartment trim panel on the left. -> 700219 Removing and installing front cover (engine compartment) Service and Repair
15. Partly remove E-box and lay it aside. -> 979019 Removing and installing relay carrier for plenum panel E-box 979019 Removing and Installing Relay Carrier, Plenum Chamber E-Box
16. Remove bulkhead from plenum panel on the left by unscrewing the three screws.
17. Remove underbody protection. -> 108019 Removing and installing engine guard 108019 Removing and installing engine guard (underbody panelling)
General warning notes
CAUTION
Increased risk when handling airbag modules.
- Injury and material damage may occur if airbag units are not handled correctly -> 69 Safety regulations for vehicles with airbag and belt tensioner - section on "General warning notes".
-> Observe safety regulations for handling airbag modules.
Technical values
Tightening torques for brake mechanics. -> 4600TW Tightening torques for brake mechanics
Tightening torques for brake hydraulics. -> 4700TW Tightening torques for brake hydraulics
Tightening torques for steering. -> 4800TW 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. -> 208055 Replacing accelerator pedal module Service and Repair
3. Remove the master cylinder on manual transmission vehicles. -> 302019 Removing and installing master cylinder Service and Repair
4. Unclip brake pedal from brake booster.
- 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. -> 701219 Removing and installing dashboard bracket 701219 Removing and installing bracket for dashboard
4. Fit the two struts for the crash support (bracket support) => Support.
Support
5. Fit steering column to bracket. -> 481519 Removing and installing steering column 48151950 Removing and Installing Steering Column
6. Fit the master cylinder on manual transmission vehicles. -> 302019 Removing and installing master cylinder Service and Repair
7. Fit frame for relay carrier.
8. Fit relay carrier. -> 9790IN Relay carrier 9790IN 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. -> 701819 Removing and installing the instrument panel 701819 Removing and installing instrument panel
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. -> 208055 Replacing accelerator pedal module Service and Repair
14. Fit dashboard trim panels.
15. Fit A-pillar trim panel. -> 705719 Removing and installing A-pillar trim 705719 Removing and installing A-pillar trim
16. Install accelerator pedal module. -> 208055 Replacing accelerator pedal module Service and Repair
17. Fit separator plate on plenum panel.
18. Fit E-box. -> 979019 Removing and installing relay carrier for plenum panel E-box 979019 Removing and Installing Relay Carrier, Plenum Chamber E-Box
19. Fit engine-compartment cover. -> 700219 Removing and installing front cover (engine compartment) Service and Repair
20. Fit cowl panel. -> 664419 Removing and installing cowl panel cover Service and Repair
21. Fit underbody protection. -> 108019 Removing and installing engine guard 108019 Removing and installing engine guard (underbody panelling)
22. Connect the battery and carry out the work required after disconnecting the battery. -> 9000IN Work instructions after disconnecting the battery
23. Read out fault memory.