Vacuum Brake Booster: Service and Repair

Removing And Installing / Replacing Brake Booster


After completing work, bleed brake system.


Remove master cylinder.

Remove storage tray.

Remove windscreen wiper arms.





Remove clip (1) and remove piston rod pin (2).

Remove nuts (3) securing booster to bulkhead.
Nuts Holding booster to bulkhead 21.4 Nm
Note: use only once.





Remove nut (1) securing coolant expansion tank to bracket.

Remove nuts (2) securing PAS reservoir to bracket.





Remove bolts (1) securing bracket to bulkhead.
PAS reservoir bracket to secondary bulkhead
M8 x 1.25 x 20 19 Nm

Remove nuts (2) securing bracket to heat shield.
Front wall heat resistant plate 7-10 Nm





Remove clip (1) securing right hand side of secondary bulkhead to tower, release fuel pipe from clip (2) and remove secondary bulkhead.

Remove secondary bulkhead seal (3).





Disconnect brake pipes (1) from ABS unit to master cylinder.
Brake pipe couplings
M10 x 1 14 Nm
M12 x 1 14 Nm





Remove bolts (1) and nut (2) securing wiper motor assembly to bulkhead. Position wiper assembly to one side.
Front wiper motor assembly fitment to bulkhead 10 Nm

Remove engine earth lead (3).
Battery earth lead to bulkhead
M8 19 Nm





Carefully remove brake booster from bulkhead and tilt away from engine.

Remove brake booster upwards out of assembly compartment.