PRE-RELEASE
Brake servo, RHD
| Brake servo, RHD |
| To remove |
| 1. |
Put on 82 93 706 Wing cover.
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Warning
| 2. |
Open the expansion tank and release the pressure. Retighten the cap.
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| 3. |
Remove the battery cover and undo the battery negative cable
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| 4. |
Raise the car.
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| 5. |
Use 88 19 096 Bleeding equipment. Connect the brake bleeder to the air nipple on the front left wheel.
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| 6. |
Open the nipple and draw out brake fluid until one of the reservoir chambers is empty.
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| 7. |
Remove the brake bleeder and close the nipple.
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| 8. |
Connect the brake bleeder to the air nipple on the front right wheel.
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| 9. |
Open the nipple and draw out brake fluid until the other reservoir chamber is empty.
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| 10. |
Disconnect the brake bleeder and close the nipple.
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| 11. |
Lower the car.
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| 12. |
Manual gearbox
: Connect the brake bleeder to the clutch bleed nipple.
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| 13. |
Manual gearbox
: Open the nipple and draw out fluid until the level in the reservoir comes below the connection.
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| 14. |
Manual gearbox
: Disconnect the brake bleeder and close the nipple.
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| 15. |
Manual gearbox
: Detach the clutch hose from the brake fluid reservoir. Brake fluid may run out, rag under.
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| 16. |
Remove
Acoustic baffle, driver
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| 17. |
Remove brake pedal link bolt.
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| 18. |
Remove the mass air flow sensor connector.
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| 19. |
Remove the air cleaner casing cover.
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| 20. |
Remove the air cleaner. Detach the intake hose and remove the air cleaner casing.
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| 21. |
Remove the crankcase ventilation pipe and hose from the turbo and camshaft cover.
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| 22. |
Remove the turbo inlet pipe and hoses.
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| 23. |
Place a jack underneath the engine. Undo the bolts on the right engine mounting to lower the engine about 30 mm.
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| 24. |
Remove the turbo heat shield.
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| 25. |
Remove the bulkhead heat shield.
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| 26. |
Remove the brake fluid level sensor connector.
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| 27. |
Remove the brake pipes from the master brake cylinder.
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| 28. |
Detach the vacuum hose from the brake servo.
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| 29. |
Remove the brake pipes from the bulkhead bracket. Hold away the brake pipes with a cable tie
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| 30. |
Remove the master brake cylinder. Use a rag under the cylinder to protect against spillage.
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| 31. |
Remove the lock clip from the turbo control arm, use 83 94 538 Circlip tool, and remove the diaphragm box from the turbo, laying it to one side.
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| 32. |
Undo the nut slightly on the turbo coolant pipe
207R : Undo the banjo screw slightly. |
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| 33. |
Undo the coolant pipe bracket from the cylinder head. Press down the pipe about 20 mm.
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| 34. |
Remove the brake servo bolts.
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| 35. |
Turn round the brake servo so the pushrod is pointing forwards under the air cleaner casing's rear body bracket. Then turn up the servo and lift it out.
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| To fit |
| 1. |
Change the brake servo gasket.
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| 2. |
Turn the brake servo so that the pushrod is pointing towards the air cleaner casing's rear body bracket. Press down the brake servo carefully.
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| 3. |
Turn the brake servo, place it on the bulkhead and fit the brake servo bolts. Use 74 96 268 Thread locking adhesive.
Tightening torque: 20 Nm (15 lbf ft) 
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| 4. |
Fit the turbo coolant pipe onto the cylinder head and tighten the nut on the turbo.
Tightening torque: 40 Nm (30 lbf ft) 207R : Tighten the banjo screw. 
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| 5. |
Fit the diaphragm box onto the turbo. Connect the pushrod and fit the clip.
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| 6. |
Fit the cylinder head. Secure with 74 96 268 Thread locking adhesive. Make sure the pushrod on the master cylinder is positioned on the brake servo pushrod.
Tightening torque: 25 Nm (18 lbf ft) 
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| 7. |
Fit the brake pipes into the brackets on the bulkhead.
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| 8. |
Fit the vacuum hose on the brake servo.
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| 9. |
Fit the brake pipes on the master cylinder.
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| 10. |
Fit the brake fluid level sensor connector.
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| 11. |
Fit the heat shield onto the bulkhead.
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| 12. |
Fit the turbo heat shield.
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| 13. |
Raise the engine with a jack and fit the bolts in the right engine mounting.
Tightening torque: 70 Nm +60° (52 lbf ft + 60°) 
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| 14. |
Fit the turbo inlet pipe and hoses.
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| 15. |
Fit the crankcase ventilation pipe and hose.
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| 16. |
Fit the air cleaner casing and air cleaner.
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| 17. |
Fit the air cleaner cover.
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| 18. |
Fit the mass air flow sensor connector.
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| 19. |
Fit the brake pedal link bolt.
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| 20. |
Fit
Acoustic baffle, driver
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| 21. |
Fit battery negative cable and battery cover.
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| 22. |
Fill with brake fluid and bleed the brake system, see
Bleeding the brake system
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| 23. |
Carry out
Procedure after disconnecting the battery
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