Brake Booster

Brake Booster

Special tools, testers and auxiliary items required

• Brake filler/bleeder unit (VAS 5234)

Removing

- Remove the driver side trim panel..

- Remove brake light switch/brake pedal switch. Refer to => [ Brake Light Switch ] Service and Repair.

- Remove bracket for brake light switch.

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

- Remove support on mounting bracket through which pressure rod of brake booster runs.






- Remove plenum chamber cover.

- Remove engine compartment seal and cover strip in area of brake booster.

- Remove facing wall of plenum chamber.

- Disconnect connector off float warning indicator sensor.

- Remove ground cable from ground point on body behind E-box, remove wiring harness from retainer behind brake booster and lay aside.

- Remove E-box from left plenum chamber from retainer and lay as far as possible aside.






- Place sufficient lint-free cloths in plenum chamber in the area of the brake master cylinder.

- Extract as much brake fluid as possible from the brake fluid reservoir using (VAS 5234).

- On vehicles with manual transmission, disconnect clutch master cylinder supply hose and seal with plug.

- Remove brake fluid reservoir, press the engagement straps toward outside at reservoir and simultaneously pull brake fluid reservoir out of sealing plugs.

- Remove left front brake line from retainer on master brake cylinder.

- Disconnect brake lines from master brake cylinder and seal brake lines using Sealing Plugs (1H0 698 311 A).

- Remove brake master cylinder nuts.

- Carefully take brake master cylinder out of brake booster.

- Pull vacuum hose out of brake booster.

- Remove brake lines from triple retainer on brake booster.

- Disconnect left front brake line at separating point in left front wheel housing.

- Remove screws from brake booster.

- Carefully remove brake booster from plenum chamber.

Installing

- Installation is performed in the reverse order of removal.

Observe the following points when installing:

Brake Pedal and Brake Booster, Connecting

- Hold ball head of push rod in front of mounting and push brake pedal in direction of brake booster, so the ball head locates audibly.

- After installing, bleed brake system and clutch. Refer to => [ Brake System, Bleeding ] Service and Repair.

After bleeding brake system, basic setting for brake pressure sensor 1 must be performed.

Vehicle Diagnostic Tester, connecting and selecting functions, refer to => [ Vehicle Diagnosis, Testing and Information System Connecting and Selection Functions ] Testing and Inspection.

- Adjust brake light switch/brake pedal switch. Refer to => [ Brake Light Switch ] Service and Repair.