Mercedes-Benz 2005 Sprinter User Manual

(2) Remove the fluid reservoir (Fig. 20) or (Fig.
21)(Refer to 5 - BRAKES/HYDRAULIC/MECHANI-
CAL/FLUID RESERVOIR - REMOVAL).
(3) Remove the brake lines Seal off the ends and
bore holes with plugs. (Fig. 20) or (Fig. 21)
(4) Remove the master cylinder mounting nuts
(Fig. 20) or (Fig. 21). Check brake booster for
damage due to leaking master cylinder. It is not
possible to repair the master cylinder.
INSTALLATION
(1) Install the master cylinder to the brake booster
(Fig. 20). Tighten to 28 N·m (248 in. lbs.).
(2) Install the brake lines (Fig. 20). Tighten to 14
N·m (124 in. lbs.).
(3) Install the fluid reservoir (Fig. 20) (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/FLUID RES-
ERVOIR - INSTALLATION).
(4) Bleed the brake system.
(5) Check the brake system for any leaks.
PEDAL
REMOVAL
(1) Remove the master cylinder (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/MASTER
CYLINDER - REMOVAL).
(2) Remove the retainer and pin for the master
cylinder push rod (Fig. 22).
(3) Remove the retainer and pin for the brake
pedal pivot bolt (Fig. 22).
(4) Unhook the spring and remove the brake pedal
(Fig. 22).
(5) Disconnect the plug connector on the stop lamp
switch (Fig. 22).
(6) Remove the bolts and remove the pedal bearing
bracket (Fig. 22).
Fig. 20 MASTER CYLINDER
1 - SUCTION GUN
2 - BRAKE FLUID CAP
3 - BRAKE FLUID LEVEL INDICATOR
4 - O-RING
5 - NUT
6 - BRAKE LINE
7 - MASTER CYLINDER
8 - FLUID RESERVOIR
Fig. 21 MASTER CYLINDER (DRW)
1 - POWER BRAKE BOOSTER
2 - RESERVOIR
3 - BRAKE LINES
4 - PRESSURE PORTS
5 - MASTER CYLINDER
Fig. 22 BRAKE PEDAL
1 - MOUNTING BOLT
2 - PEDAL BEARING BRACKET
3 - STOP LAMP SWITCH
4 - CLIP
5 - PIVOT BOLT
6 - RETURN SPRING
7 - PEDAL
8 - PUSH ROD BOLT
9 - PUSH ROD
10 - CLIP
11 - BOLT
12 - WASHER
5 - 18 BRAKES - BASE VA
MASTER CYLINDER (Continued)

Mercedes-Benz 2005 Sprinter Specifications

General

Brand	Mercedes-Benz
Model	2005 Sprinter
Category	Automobile
Language	English