Vacuum Brake Booster: Service and Repair

Brake servo, LHD
To remove
1. Remove the lower dashboard section on the driver's side.
2. Remove the master cylinder.
3. Remove the ABS unit.
4. Remove the ABS unit bracket.





5. Detach the vacuum hose from the brake servo.
6. Remove the connector cover.





7. Unplug the connector of the engine harness.
8. Cut off the cable tie.
9. Remove the clip.
10. Unplug the connector of the water valve. Be careful so as not to break the connector.
11. Remove the bracket of the engine harness.
12. Remove the brake servo retaining nuts from the bracket.





13. Remove the clip on the pushrod and lift out the brake servo.

To fit
1. Depress the brake pedal by means of a brake pedal clamp.

Note: Make sure the clip is correctly positioned on the pushrod.

2. Connect the pedal and brake servo pushrods. Make sure that the brake pedal pushrod reaches far enough that it is secured by the clip.





3. Position the brake servo in the bracket.
4. Remove the brake pedal clamp.
5. Fit the brake servo nuts.
Tightening torque: 24 Nm (18 ft. lbs.)
6. Depress the brake pedal and pull out the pedal switch's self-adjuster.
Check that the pushrod is positioned correctly by pulling the brake pedal rearwards. The pedal should feel dead.
7. Fit the lower dashboard section.
8. Attach the vacuum hose to the brake servo.
9. Fit the master cylinder.
10. Fit the ABS unit bracket.





11. Attach a new cable tie.
12. Fit the clip.





13. Plug in the water valve connector.
14. Fit the bracket of the engine harness.
15. Plug in the connector of the engine harness.
16. Plug in the connector of the anti-theft alarm breaker.
17. Fit the ABS unit.
18. Manual gearbox: Fit clutch hose to the brake fluid reservoir.
19. Fit the main fuse box.
20. V6 diesel engine: Fit the turbo unit heat shield.
21. Fit the battery and battery cover.
22. Fill with brake fluid and bleed the brake system.

Brake servo, RHD
To remove





1. Remove the master cylinder.
2. Remove the wiper arms and cover panel over the wiper mechanism.
3. Disconnect the vacuum hose from the brake servo.
4. Remove the crankcase breather valve and its hoses to provide more working space.
5. Undo the brake servo bracket's retaining bolt and two retaining nuts from the front bulkhead partition.
6. Remove the cover panel under the dashboard.





7. Unhook the brake pedal return spring.
8. Remove the clip and the pedal's through pin.
9. Lift out the brake servo.
10. If fitting a replacement unit, transfer the bracket to the new brake servo.

To fit





1. Correctly position the brake servo bracket and tighten the retaining bolt and two retaining nuts.
2. Fit the crankcase breather valve and hoses.
3. Connect the vacuum hose to the brake servo.
4. Fit the cover panel and wiper arms.
5. Fit the master cylinder.
6. Fit the through pin and circlip and hook the return spring in place.

Brake servo, V6 diesel, RHD
To remove
1. Raise the car.
2. Remove the lower engine cover.





3. Lower the car to the floor.
4. Remove the master cylinder.
5. Place a jack with rubber pad under the oil pan. Place the pad on the edge.
Raise the engine with the jack so that it is supported when the engine mounting is removed.





6. Remove 5 bolts from the right-hand engine mounting.
7. Lower the engine carefully with the jack.
Place a wedge between the AC compressor and the subframe to prevent damaging the pipes.
8. Remove the rubber moulding.
9. Remove the wiper arms.
10. Remove the cover over the wiper unit.
11. Detach the vacuum hose from the brake servo. Cut off the cable tie.





12. Undo the brake servo bracket's retaining bolt and two retaining nuts from the front bulkhead partition.
13. Remove fuse no. 1.





14. Remove the cover panel under the dashboard.





15. Remove the clip.
16. Turn the servo 45° anticlockwise and lift out the brake servo.
17. If fitting a replacement unit, transfer the bracket to the new brake servo.

To fit
1. Lift the brake servo in place. The servo must be in the wrong position when it is lifted into the car.
Guide the pushrod in place while positioning the servo.





2. Position the servo pushrod into the brake pedal pushrod.

Note: Make sure the pushrods link up and that the rubber gaiter does not come loose from the bulkhead.





3. Turn the brake servo to the correct position and fit the retaining nuts and bolt loosely.
4. Tighten the nuts and the bolt.
Tightening torque 24 Nm (18 ft. lbs.)
5. Fit the locking clip onto the brake pedal pushrod.
Depress the pedal so that the pushrods lock together. Pull up the pedal to make sure the clip is locked.
Depress the brake pedal and pull out the pedal switch adjusting pins. Pull up the brake pedal.
6. Attach the vacuum hose to the brake servo.
7. Fit the master cylinder.
8. Lower the engine carefully with the jack. Remove the wedge.
9. Fit the bolts on the right-hand engine mounting.
Tightening torque 40 Nm +60° (30 ft. lbs. +60°)
Lower the jack and remove it.





10. Fit the cover over the wiper unit.
11. Fit the rubber moulding.
12. Fit the wiper arms.
13. Raise the car.





14. Fit the lower engine cover.





15. Fit the cover under the dashboard.