Brake master cylinder Tightening torques Brake booster mounting nuts 21 Nm Rigid brake line nipples on the master brake cylinder 14 Nm Removal Place the vehicle on a two-post lift. Remove the top engine cover (if there is one). Disconnect...
Brake line between master cylinder and front right brake caliper Tightening torques Brake line nipple on master cylinder 14 Nm Brake line nipple on brake hose 14 Nm Removal Place the vehicle on a two-post lift. Install a pedal hold down device on the brake pedal to restrict brake...
Brake line between master cylinder and front left brake caliper Tightening torques Brake line nipple on master cylinder 14 Nm Brake line nipple on brake hose 14 Nm Removal Place the vehicle on a two-post lift. Install a pedal hold down device on the brake pedal to restrict brake...
Brake booster check valve Removal Models with K9K engine Remove the top engine cover. All models Disconnect the check valve at point (1) from the brake booster. Pull the check valve out by rotating it to remove it from the rubber sealing washer....
Vacuum brake booster Tightening torques: Brake booster mounting nuts - 21 Nm. Removal Place the vehicle on a two-post lift. Disconnect the battery. Remove: master brake cylinder, check valve (1) from the brake booster. Remove, from the...
Vacuum pump (K9K engine) Tightening torques: Vacuum pump mounting bolts - 21 Nm. Removal Remove: top engine cover, air intake pipe. Tilt the air filter housing slightly to gain access to the vacuum pump. Models with K9K engine version 796...
Pedal assembly fork Tightening torques: Pedal fork mounting nuts - 21 Nm. Removal Remove the brake light switch. Remove the connecting shaft (1) between the brake pedal and the brake booster rod: unlock the axle according to (2), remove...
Accelerator pedal (4x4 drive) Tightening torques: Accelerator pedal mounting bolts - 8 Nm. Removal Turn off the ignition. Disconnect the accelerator pedal position sensor connector (1). Remove: accelerator pedal mounting bolts (2) on the pedal...
Accelerator pedal (K4M engine with 4x2 drive) Tightening torques: Pedal mounting nuts - 21 Nm. Removal Loosen the special nut (1) securing the foam soundproofing pad to the left accelerator pedal assembly mounting nut. Remove: nuts (2) for fastening the accelerator...
Accelerator pedal cable (K4M engine with 4x4 drive) Removal Disconnect the throttle cable at point (1). Push the cable housing stopper into the engine compartment. Disconnect the throttle cable at point (6). Remove the throttle cable adjusting bracket (7). Remove the...
Brake pedal — removal and installation Tightening torques: Brake pedal axle nut - 16 Nm. Removal Remove the brake light switch from the clutch pedal. Remove the connecting shaft (1) between the brake pedal and the brake booster rod: unlock the axle according...
Brake light switch Removal Remove the lower instrument panel trim (depending on the equipment level). Disconnect the brake light switch connector. Turn the brake light switch (1) a quarter turn counterclockwise. Remove the brake light...
Parking brake lever Tightening torques: Parking brake lever mounting bolts - 8 Nm. Removal Remove the center console. To loosen the cables in the equalizer area, unscrew the adjusting nut (1) of the parking brake, noting the dimension (X)...
List and location of clutch drive components 1. Cable clutch drive 1 - Clutch cable 2 - Clutch pedal 3 - Clutch release fork 4 - Clutch release bearing This drive does not have automatic clearance compensation 2. Hydraulic clutch drive 5 - Fluid supply pipeline to...
Clutch pedal — removal and installation Tightening torques: Pedal axle nut - 21 Nm. Removal Unscrew the nut (4) of the pedal axle (2). Pull out the axle (2) and release the clutch pedal. Remove the clutch pedal (3). Installation Lubricate the axle with...
Clutch pedal travel sensor Removal Remove: driver side instrument panel lower cover holders (1), lower cover of the instrument panel on the driver's side (2). Disconnect the connector (3) of the clutch pedal travel sensor. Turn the clutch pedal...
Clutch hydraulic drive — air removal Remove air if: free running, the pedal is in the middle position, when pedal 8 is pressed, difficult gear shifting. Place the vehicle on a two-post lift. Remove the engine oil pan guard. There are several modifications...
Bleeding procedure if no clutch hydraulic system parts are removed 1 - Air removal with ARC50 Secure the clutch pedal in the up position with a strap attached to the steering wheel to ensure the integrity of the hydraulic drive during the bleeding operation. Note: Be careful not to...
Air bleeding procedure if clutch hydraulic drive parts are removed Attention! The clutch master cylinder line must be disconnected from the brake fluid reservoir nipple to prevent foreign bodies from entering the brake system hydraulic drive. Take care to prevent leaking brake fluid...
Clutch master cylinder Tightening torques: Expansion tank nuts - 8 Nm. Removal Place the vehicle on a two-post lift. Remove the engine oil pan guard. Unscrew the two nuts securing the expansion tank. Move the expansion tank to the side....
Clutch hydraulic drive — removal and installation Tightening torques: Expansion tank nuts - 8 Nm. Note: When performing any work on the clutch hydraulic drive be sure to remove the air, from the circuit between the tank and the air bleed nipple, from the circuit...
Gear shift lever housing Tightening torques Gear shift lever housing mounting bolts 21 Nm Exhaust Pipe Fasteners 22 Nm Expansion tank nuts 8 Nm Removal Place the vehicle on a two-post lift. Disconnect the battery. Loosen the expansion tank...
Parking brake cables Removal Place the vehicle on a two-post lift. Remove: center console, rear wheels, rear wheel brake drums. Remove the parking brake cable (1) from the lever using pliers and a screwdriver. Disconnect the parking brake...
Brake booster vacuum — leak test When checking the brake booster for leaks, make sure that it is completely sealed to the brake master cylinder. If there is a leak, replace the gasket (A). Checking the tightness of the brake booster should be performed...
List and location of ABS components 1 - Hydraulic unit 2 - Steering wheel angle sensor 3 - ABS warning light on the instrument panel 4 - Brake light switch 5 - Fuse box 6 - Diagnostic connector 7 - Angular and lateral acceleration sensor 8 - ESP switch 9...
Hydraulic unit of the brake system with ABS Tightening torques ABS hydraulic unit mounting bolts on bracket 8 Nm Rigid piping fittings on the hydraulic unit 13 Nm Nut for fastening the hydraulic unit ground wire 8 Nm Removal Disconnect the battery. Install a...
Front wheel speed sensor Tightening torques: Front wheel speed sensor mounting bolt - 7 Nm. Removal Place the vehicle on a two-post lift. Remove: front wheel, front mudguard. Disconnect the front wheel speed sensor connector (1). Disconnect the...
Rear wheel speed sensor Tightening torques Rear wheel speed sensor shield mounting nuts 14 Nm Wheel speed sensor mounting bolt 7 Nm Removal Place the vehicle on a two-post lift. Remove the rear wheel. Disconnect the rear wheel speed sensor...