Brake Booster

Brake booster

Special tools:
999 7103 Lifting beam 999 7103 Lifting Beam
999 5185 HOOK 999 5185 Hook

Note! The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Preparatory work




Ignition off.

Remove:
- the battery. See: Battery Removal and Replacement
- the 3 screws
- the temperature sensor connector from the battery box
- the battery box.

Removal

Removing the windshield wiper motor
Remove the windshield wiper motor. See: Wiper mechanism, windshield Service and Repair.

Removing the protective cover over the power brake booster





Remove:
- the cable from the 2 clips (3). Place the cable to one side
- the 2 x screws (4)
- the splash guard.

Removing the air conditioning (A/C) pipe / hose
Drain the refrigerant. See: Refrigerant, draining Refrigerant, Draining.
Remove the low pressure pipe. See: Refrigerant pipe condenser to expansion valve Refrigerant Pipe Condenser to Expansion Valve.
Disconnect the high pressure pipe from the cowl panel. Pull the pipe out of the clip. Place the pipe to one side.

Removing the pedal sensor





Remove:
- the pressure sensor (1)
- the connector (2)




Remove the pedal sensor. Widen the snap ring and pull out the pedal sensor.

Hint: The opening on the snap ring points straight down. The snap ring does not need to be completely removed, just opened.

Note! Ensure that the O-ring is also removed.

Removing the brake pipe
Remove the two brake tubes between the master cylinder and the coupling.

Removing the master cylinder
Remove the master cylinder. See: Master cylinder, brake, R.H.D Master Cylinder, Brake, R.H.D.

Removing soundproofing panels
Remove the soundproofing panel. See: Instrument panel lower Instrument Panel Lower.

Removing the timing covers





Remove:
- the bolts, x2
- the upper timing cover.




Remove the front timing cover.

Removing the splash guard under the engine
Turn the clips 90° and remove the splash guard.

Removing right engine pad
Remove the right-hand engine pad. See: Engine support insulator, right, B5254T7 Engine Support Insulator, Right.

Removing the power brake booster




Remove the pin for the power brake booster.

Note! The pin cannot be removed entirely. It must be replaced with a new pin on installation.





Remove:
- the 4 nuts
- the power brake booster.

Installation

Note! For tightening torques, see Specifications. Tightening Torque.

Installing the power brake booster

Install:
- the new power brake booster
- the 4 M8 nuts
- the new pin for the push rod.

Installing the pedal sensor




Press in the new pedal sensor.

Note! Use a new O-ring. The pedal sensor can only be installed in one position, i.e. with the locating pin pointing straight up. Lubricate with soap solution and install the pressure sensor (1). Connect the electrical connector (2).

Installing the master cylinder
Install the master cylinder. See: Master cylinder, brake, R.H.D Master Cylinder, Brake, R.H.D.

Installing the brake pipes
Install the two brake tubes (3).

Bleeding brake systems
Bleed the brake system. See: Brake system bleeding Brake System Bleeding.
Check that the brake pipe connections are sealed.
Check the brake fluid level.

Installing the right engine pad
Install the engine pad. See: Engine support insulator, right, B5254T7 Engine Support Insulator, Right.
Remove lifting beam and hook.

Installing the air conditioning (A/C) pipe / hose

Install:
- the high pressure pipe in the clip
- the high pressure pipe in the cowl panel
- the low pressure pipe. See: Refrigerant pipe condenser to expansion valve Refrigerant Pipe Condenser to Expansion Valve
- fill with refrigerant. See: Refrigerant, filling Refrigerant, Filling.

Installing the timing covers

Install:
- front timing cover
- the upper timing cover
- the 2 M6 screws.

Installing the splashguard under the engine
Install the splash guard. Turn the clips 90°.

Installing the protective cover over the power brake booster





Install:
- the protective cover
- the 2 clips (4)
- the 2 clips (3).

Installing the windshield wiper motor
Install the windshield wiper motor. See: Wiper mechanism, windshield Service and Repair.

Installing the soundproofing panel
Install the soundproofing panel. See: Instrument panel lower Instrument Panel Lower.

Finishing

Install:
- the temperature sensor connector in the battery box
- the battery box
- the 3 M6 screws
- the battery as shown: Battery Removal and Replacement.