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Sprinter (1995-2000, diesel) Vito 1 (1996-2003) Vito 2 (2003-2014, diesel) Vario 814D (1996-2003, diesel)
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  • Removal and installation the brake booster

Removal and installation the brake booster (Mercedes-Benz Sprinter 903)

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Figure 300. Brake booster: 1 - vacuum hose; 2 - amplifier; 3 - gasket; 4 — nut, 25–28 N·m; 5 —…

Figure 300. Brake booster: 1 - vacuum hose; 2 - amplifier; 3 - gasket; 4 — nut, 25–28 N·m; 5 — pusher finger


The work on removing the booster is in many ways similar to the work described above on removing the master brake cylinder, especially since the latter must be removed before dismantling the booster. When working, use the drawing as a guide 300.

After removing the main brake cylinder, remove the cotter pin and remove the pusher pin 5, unscrew the fastening nut 4 from the pedal compartment. Remove the gasket 3 located on the rear side.

Assembly is carried out in reverse order. When installing, be careful not to pinch the brake fluid level indicator lamp wire. Tighten the 4 fastening nuts to a torque of 25–28 N·m.

After starting the engine, check the operation of the amplifier as described above.

Sometimes brake fluid from the master cylinder leaks into the booster. If after removal it is established that there was more than 100 ml of brake fluid in the booster, the booster must be replaced.
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Mercedes Sprinter / Brake system
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Brake booster — general information
Replacing the rear parking brake cables
Replacing the front parking brake cable
Adjusting the parking brake cables
Adjusting the parking brake shoes
Bleeding brakes
Anti-lock braking system (ABS)
Vacuum pump — removal and installation
Brake system specifications
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Vario 814D (1996-2003, diesel) 
  • General information
  • Maintenance
  • Power unit
  • Engines 602.984/985
  • Engines 904.908/914/923/936
  • Transmission
  • Clutch
  • Manual gearbox 711.613
  • Manual gearbox 710.64/66
  • Manual gearbox 715.051
  • Automatic gearbox 723.345
  • Power take-off box
  • Chassis
  • Front suspension
  • Rear suspension
  • Steering
  • Brake system
  • Body and electrical equipment
  • Interior (internal elements)
  • Exterior (external elements)
  • Heater and air conditioner
  • Electrical diagrams
Vito 2 (2003-2014, diesel) 
  • General information
  • User manual
  • Maintenance
  • Diesel engine OM646
  • Engine repair
  • Cooling and lubrication system
  • Power and exhaust system
  • Transmission
  • Clutch
  • Car gearbox
  • Chassis
  • Front suspension
  • Rear suspension
  • Steering
  • Brake system
  • Body
  • Body elements
  • Electrical equipment
  • Equipment and devices
  • Security systems
  • Electrical circuits
Vito 1 (1996-2003) 
  • General information
  • User manual
  • Maintenance
  • Petrol engines 2.0 l
  • Engine repair
  • Lubrication system
  • Cooling system
  • Power and control system
  • Petrol engines 2.8 l
  • Engine repair
  • Lubrication system
  • Cooling system
  • Power and control system
  • Diesel engines 2.3 l
  • Engine repair
  • Cooling system
  • Lubrication system
  • Turbocharging and recycling
  • Power and control system
  • Diesel engines 2.2 l
  • Engine repair
  • Cooling system
  • Lubrication system
  • Turbocharging and recycling
  • Power and control system
  • Transmission
  • Clutch
  • Mechanical gearbox
  • Automatic gearbox
  • Chassis
  • Front suspension and wheels
  • Rear suspension
  • Steering
  • Brake system
  • Body
  • Exterior (external elements)
  • Interior (internal elements)
  • Electrical equipment
  • Equipment and devices
  • Heater and air conditioner
  • Electrical circuits
Sprinter (1995-2000, diesel) 
  • General information
  • Introduction to the guide
  • Maintenance
  • Power unit
  • Engine repair
  • Lubrication system
  • Cooling system
  • Power and exhaust system
  • Transmission
  • Clutch
  • Mechanical gearbox
  • Automatic gearbox
  • Front axle
  • Rear axle and cardan
  • Chassis
  • Car suspension
  • Steering
  • Brake system
  • Tires and wheels
  • Electrical equipment
  • Equipment and devices
  • Headlights and lighting
  • Power devices
  • Electrical circuits
 
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