Brakes and Traction Control: Service and Repair
WM 461019 Removing and installing mounting saddle
Preliminary work for removing and installing mounting saddle
1. Remove wheel housing liner at the left. -> 505619 Removing and installing front wheel housing liner - section on "Removing" Service and Repair
2. Remove the brake pedal. -> 460519 Removing and installing brake pedal - section on "Removing" Service and Repair
3. Remove the left cross panel. -> 508119 Removing and installing cross panel - section on "Removing" Service and Repair
4. Remove engine guard. -> 108019 Removing and installing engine guard - section on "Removing" 108019 Removing and installing engine guard
5. Loosen relay box. -> 970955 Replacing sub-part of wire harness in engine compartment at the front left - section on "Removing" 970955 Replacing sub-part of wire harness in engine compartment at the left
Removing mounting saddle
Installation position of mounting saddle
1. Remove the relay carrier at the right -2- next to the brake pedal.
Removing relay carrier
1.1. Loosen the fastening screw -1- on the relay carrier -2- at the right next to the brake pedal.
1.2. Pull the relay carrier down and to the rear -A- and remove it from the lower guide.
1.3. Pull the top guide -3- for the relay carrier up -B- out of the bracket -4- on the mounting saddle.
2. Loosen the fastening nuts -1- on the brake booster under the dashboard.
Removing brake booster
3. 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).
Opening cable duct
4. Unclip the fixing clips -1- from the cable duct -2- on the mounting saddle using a suitable tool, e.g. pointed-nose pliers.
Clips on cable duct
5. Loosen the top fastening screws -1- for the mounting saddle in the plenum panel.
Fastening screws for mounting saddle at the top
6. Fit the fastening screw -1- for the mounting saddle at the bottom in the plenum panel, under the brake booster.
Fastening screw for mounting saddle in plenum panel at the bottom
7. Loosen the fastening screws -1- for the heat shield -2- at the left of the primary catalytic converter on the longitudinal member.
Heat shield, left
8. Unscrew the bottom fastening screw -1- for the mounting saddle through the opening in the wheel housing.
Fastening screw for mounting saddle at the bottom
9. Remove mounting saddle from the vehicle.
Installing mounting saddle
1. Fit mounting saddle in the vehicle.
2. Fit fastening screw -1- at the bottom.
Fastening screw for mounting saddle at the bottom
3. Fit fastening screws -1- for the heat shield -2- at the left of the longitudinal member.
Heat shield, left
4. Fit the fastening screw -1- for the mounting saddle at the left under the brake booster.
Fastening screw for mounting saddle in plenum panel at the bottom
5. Fit the top fastening screws -1- for the mounting saddle in the plenum panel.
Fastening screws for mounting saddle at the top
6. Pre-fit tie-wraps -1- in the cable duct -2-.
Pre-fitting tie-wraps in cable duct
7. Clip in fixing clips -1- from the cable duct -2- at the mounting saddle.
Clips on cable duct
8. 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
9. Secure main wire harness on cable duct.
Main wire harness at the side of the cable duct
10. Fit the fastening nuts -1- for the brake booster under the dashboard. -> 4X00IN Tightening torques for brake mechanism 4X00IN Tightening torques for brake mechanics
Fitting brake booster
11. Fit the relay carrier.
Fit relay carrier at the right
11.1. Insert the guide -3- for the relay carrier at the right next to the brake pedal from above -B- and into the holder -4-.
11.2. Press the relay carrier -2- down into the guide -A-.
11.3. Fit the fastening screw -1-.
Subsequent work
Subsequent work for removing and installing mounting saddle
1. Install brake pedal. -> 460519 Removing and installing brake pedal - section on "Installing" Service and Repair
2. Fit the left cross panel. -> 508119 Removing and installing cross panel - section on "Installing" Service and Repair
3. Fit the relay box. -> 970955 Replacing sub-part of wire harness in engine compartment at the front left - section on "Installing" 970955 Replacing sub-part of wire harness in engine compartment at the left
4. Install wheel housing liner at the left. -> 505619 Removing and installing front wheel housing liner - section on "Installing" Service and Repair
5. Fit engine guard. -> 108019 Removing and installing engine guard - section on "Installing" 108019 Removing and installing engine guard