Peugeot 308: Removing - refitting : Electrical brake servo

ESSENTIAL : Observe the safety and cleanliness recommendations .

ESSENTIAL : All personnel carrying out work on a vehicle fitted with traction batteries must have received specific electric vehicle training and be authorised to work on these vehicles (observe the regulations in force in the respective country).

1. Parts which must always be replaced

Description	Quantity
Seal (Electrical brake servo / Body)	1
Nuts (Pedal bracket)	4

2. Tooling

Tool	Reference	Description
	[0818-Z][CH-52288]	Tool for unclipping the connection between the pedal bracket ball joint / Electrical brake servo (Improvement of the tool [0818] : Addition of a handle)

3. Preliminary operations

PHEV DRIVE TRAIN

CAUTION : Perform the operations that are required before disconnecting the ancillaries batteries .

Disconnect the ancillaries batteries (Following the specific procedure).

Drain the brake fluid reservoir as completely as possible ; Using a clean syringe.

Remove the air inlet union (1).

Disconnect the connector (at "a").

PHEV DRIVE TRAIN

Remove :

• The ancillaries battery ‎1 and its bracket
• The master-cylinder

4. Removing

Disconnect :

• The connector (at "b")
• The connector (at "c")

Remove the air union (2).

CAUTION : Do not damage the electric brake servo gaiter.

Move aside the tabs (at "d") ; Using the tool [0818-Z / CH-52288] (from below).

Hold tool ‎[0818-Z / CH-52288]‎ in place, pull gently on the brake pedal and disconnect the electric brake servo rod ‎‎ from the brake pedal ‎.

Remove :

• The nuts (3)
• The pedal bracket

Remove :

• The electric brake servo ‎(4)
• The electric brake servo ‎(4) seal ‎

5. Refitting

PHEV DRIVE TRAIN

CAUTION : Observe the tightening torques .

N.B. : Each time it is refitted, take care not to damage the brake servo protection gaiter.

Refit :

• The new electric brake servo ‎(4) seal ‎
• The electric brake servo ‎(4)
• The pedal bracket
• The new nuts (3)

Couple the electric brake servo rod ‎‎(4) to the brake pedal ‎ by depressing the brake pedal ‎.

Reconnect :

• The connector (at "c")
• The connector (at "b")

6. Additional operations

PHEV DRIVE TRAIN

Refit the master cylinder .

Fill and bleed the braking circuit .

Clean brake fluid from the surroundings.

Reconnect the connector (at "a").

Refit :

• The air union (2)
• The air inlet union (1)
• The ancillaries battery ‎1 and its bracket

CAUTION : Perform the operations that are required after reconnecting the ancillaries batteries .

Reconnect the ancillaries batteries (Following the specific procedure).

ESSENTIAL : Apply the brakes several times, gently and progressively, with the engine running, before driving the vehicle.

CAUTION : Check that there are no leaks of brake fluid.

Check the brake fluid level and top up if necessary.