Vacuum Brake Booster: Service and Repair
Removing And Installing / Replacing Brake BoosterNote:
- Refer to General Information, see Antilock Brakes / Traction Control Systems, Description and Operation.
- After completing work, bleed brake system, refer to Brake Bleeding, Service and Repair. Service and Repair
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.
Tightening torque:
- Nuts Holding booster to bulkhead 21.4 Nm
- 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.
Tightening torque:
- PAS reservoir bracket to secondary bulkhead M8 x 1.25 x 20 19 Nm
Remove nuts (2) securing bracket to heat shield.
Tightening torque:
- 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.
Tightening torque:
- 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.
Tightening torque:
- Front wiper motor assembly fitment to bulkhead 10 Nm
Remove engine earth lead (3).
Tightening torque:
- 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.