Brake Booster

Brake Booster

Special tools, testers and auxiliary items required

• Hose clamps up to 25 mm dia. (3094)

Removing

- Note radio code (for vehicles equipped with coded anti-theft radio).

- Disconnect battery.

- Clamp return hose of clutch master cylinder shut using hose clamps (3094).

- Disconnect supply hose for clutch master cylinder.

- Remove control module and hydraulic unit:

• Vehicles with ABS Mark 20 IE, up to 09.00 => [ ABS Control Module and Hydraulic Unit ] Service and Repair.

• Vehicles with ABS Mark 60 from 10.00 => [ ABS Control Module and Hydraulic Unit ] Service and Repair.

- Disconnect vacuum hose from brake booster.

With TDI Engine

- Remove bracket for wiring harness from vacuum pump.

Continuation for All

- Disconnect connector - 1 - from bracket - 2 -.





- Disconnect harness connector - 1 -.

- Remove trim below instrument panel.

- Remove bolts - 1 -.





- Remove cover - A -.

- For vehicles with manual transmission, remove connecting sheet between clutch and brake pedal.





- Remove brake light switch - 1 -.

- Disconnect brake pedal from brake booster => [ Brake Pedal to Brake Booster, Disconnecting and Connecting ] Brake Pedal to Brake Booster, Disconnecting and Connecting.

- Remove brake booster - arrows -.





- Thread brake booster out with brake master cylinder toward front and remove.

Installing

Installation is performed in reverse order of removal.

- Adjust brake light switch for vehicles from 03.00 => [ Brake Light Switch, Adjusting, from 03.00 ] Adjustments.

- Adjust and lock brake light switch for vehicles up to 11.06 => [ Installing, adjusting and locking ] Brake Light Switch, Through 11.06.

- Adjust and lock brake light switch for vehicles from 11.06 => [ Installing, adjusting and locking ] Brake Light Switch, From 12.06.

- After installing, bleed brake system:

• Vehicles with or without ABS Mark 20 IE up to 09.00 => [ Brake System Bleeding General Information ] Brake System Bleeding General Information.

• Vehicles with ABS Mark 60 from 10.00 => [ Brake System Bleeding General Information ] Brake System Bleeding General Information.

- Bleed clutch