Installing

Hydraulic brake servo, installing

- disconnect return line from reservoir
- remove hose and shorten by approx. 20 mm
- position new gasket onto new brake servo
- for sealing between brake servo and bulkhead
- install new brake servo at bulkhead
- tightening torque: 20 Nm (15 Nm)

NOTE: In the new servo design, the weep hole located next to the warning light switch must face downward (toward the ground).

CAUTION: When routing the pressure and return lines, carefully bend them in large arcs. Do not kink the lines.




- loosely install return line 1 to new brake servo
- install return line 1 on reservoir
- check that routing of return line 1 is free of kinks and interference
- tighten return line 1 at brake servo
- position clevis at brake pedal and fasten with pin
- install new securing clip onto clevis pin
- install footwell outlet
- install storage compartment, drivers side
- connect wiring 2 at switch

CAUTION: When routing the pressure and return lines, carefully bend them in large arcs. Do not kink the lines.




- route pressure line 3 as shown, free of interference, then tighten

CAUTION: Pressure and return lines MUST be connected to their proper locations, or damage and leakage will result.




For LONG-version master cylinders:
- position intermediate piece 4 on push rod
- do NOT re-install 0-ring

Original brake servo with SHORT-version master cylinder:

For SHORT-version master cylinders:
- do not re-install flange a
- do not re-install 0-ring

- install master cylinder on brake servo
- remove sealing plug from brake master cylinder
- install brake fluid reservoir
- for vehicles with manual transmission ONLY:
- install hose (for clutch master cylinder), onto brake fluid reservoir
- refill brake fluid reservoir and bleed brakes
- for vehicles with manual transmission ONLY:
- bleed clutch
- re-connect battery GND strap
- start engine and check hydraulic brake servo system for leaks
- check hydraulic oil level; refill as necessary