Brake booster Citroën Peugeot 9821104980 0204J00547 1635255280

Descrizione

BOSCH brake booster for Stellantis vehicles
From a vehicle with 33,000 km mileage

Part description

Used BOSCH brake booster for vehicles in the Stellantis group, identifiable by the numbers 9821104980, 0204J00547 and 1635255280. The booster reduces the force required to press the brake pedal and contributes to comfortable brake operation. Proper functioning of this component is important for safe braking.

The part comes from a vehicle with 33,000 km mileage and offers a replacement for a faulty booster with a used part whose donor vehicle’s mileage is known. The documentation lists the models Citroën Berlingo K9, Peugeot Partner III, Peugeot Rifter, Opel Combo E K9 and Fiat Doblo III. When selecting a part, compare not only the product numbers, but also the mounting, connections and design of the control mechanism with the original part.

Technical information

• Manufacturer: BOSCH
• Model: Citroën Berlingo K9; FIAT DOBLO III; OPEL COMBO E K9; PEUGEOT PARTNER III; PEUGEOT RIFTER
• Part type: brake booster
• Vehicle group: Stellantis
• Condition: used part
• Donor vehicle mileage: 33,000 km
• Other numbers: not specified

The model names are taken from the labels provided. Specific model years, engine variants and brake system versions are not specified; therefore, the model name alone is not sufficient to determine whether the part is suitable.

Product codes

• Product codes: 9821104980, 0204J00547, 1635255280

The numbers listed can be used to search for the booster and compare it with the markings on the original part. The documentation does not specify the relationship between the individual numbers or the extent to which they are interchangeable.

Installation recommendations

The following procedure is general and typically applies to replacing a brake booster. Access to the part, connection method and exact steps depend on the specific model and vehicle configuration. This is a safety-critical component: installation requires appropriate experience and compliance with the manufacturer’s service documentation.

1) Before installation

• First determine the cause of the fault. A hard brake pedal or weak brake assistance does not necessarily mean the booster itself is damaged.
• Compare the product numbers, housing shape, mounting points, connection to the master cylinder, control rod and connections with the old part.
• Inspect the used part: check for deformation, cracks, corrosion, threads, any seals present and possible traces of fluid.
• If the part is damaged or differs in design, stop installation and arrange for a professional assessment.

2) Tools and materials required

In general, prepare suitable hand tools, a torque wrench, lighting, protective gloves and clean materials to protect disconnected connections. If the work requires opening the hydraulic circuit, equipment for bleeding the brakes will also be needed. Determine the requirements for sealing and retaining components according to the service documentation for the specific vehicle.

3) Step-by-step installation procedure

1. Park the vehicle on level ground, secure it against movement and read the prescribed replacement procedure.
2. Switch off the ignition. Secure the electrical system and release any residual energy in the brake assistance system as specified by the manufacturer.
3. Remove the components necessary to gain access. Record the routing of connections and the position of retaining components, for example by taking photographs.
4. Clean the area around the connections to prevent dirt from entering the connected systems when they are disconnected.
5. Depending on the configuration, disconnect the booster connections. Release hoses, any connectors and their retainers without using force.
6. Release the master cylinder according to the service procedure. If it can remain connected to the pipes, support it securely; do not leave it hanging from the lines. Protect any open hydraulic connections from contamination.
7. Disconnect the control mechanism, release the booster mountings and carefully remove the part without damaging surrounding components.
8. Compare the two parts side by side and check the mating surfaces. Do not adjust the rod length or its setting by guesswork.
9. Position the replacement booster, secure it and correctly fasten the control linkage. Tighten and make any adjustments strictly according to the vehicle manufacturer’s specifications.
10. Reinstall the master cylinder, connections and all other removed components. Check that the lines are not pinched, stretched or kinked.
11. If the hydraulic circuit was opened, bleed it using the prescribed procedure. Before moving the vehicle, complete the leak check and verify that the connections are secure and the brakes are functioning correctly.

4) Post-installation checks and test drive/function verification

With the vehicle stationary, check the operation of the brake assistance, pedal return and tightness of the affected connections according to the service documentation. Also check that the brakes do not remain applied after the pedal is released. Only carry out a test drive after the stationary checks have been completed successfully, initially at low speed in a safe area away from normal traffic. If the pedal behaves unusually, fluid leaks or braking is inadequate, do not use the vehicle and have the fault repaired.

5) Most common installation errors + how to prevent them

• Confusing similar versions: compare the markings and design details, not just the appearance of the housing.
• Replacing the part without determining the cause of the fault: check the related components of the brake assistance system before installation.
• Incorrect rod adjustment: follow the service procedure and do not make adjustments by guesswork.
• Straining the brake pipes: support the released cylinder and do not bend the lines by force.
• Damaged seals or unsecured connections: during assembly, check the fit, condition of the sealing surfaces and all retainers.
• Skipping bleeding or a functional check: after opening the hydraulic system, complete the prescribed bleeding procedure and verify that the entire affected system is functioning before driving.

Reasons why the part may become damaged

In general, the following factors may cause damage to a brake booster. This is not a description of faults identified on the part offered:

• Aging seals and wear of moving parts, which may lead to leaks or irregular operation.
• Moisture and corrosion affecting the housing, connections or control mechanism.
• Brake fluid entering from a leaking master cylinder, if the assembly design allows this.
• Mechanical damage caused by an accident, dropping the part, improper handling or forceful installation.
• Incorrect adjustment or excessive strain on the control mechanism, which interferes with proper operation.

In vacuum systems, similar symptoms may also be caused by leaking hoses, a faulty check valve or a problem with the vacuum source. It is therefore important to assess the system as a whole before replacement and address any underlying cause of the damage.