Brake Booster, L.H.D

Brake booster

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

Removal

Removing splash guards





Remove:
- the 2 clips
- the protective cover over the brake fluid reservoir.





Remove:
- the plastic nut
- the protective cover for the firewall.

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 heat deflector plate





Remove:
- the heat deflector plate. Pull straight out
- the hoses from the clip.

Removing the brake pipe





Remove:
- the two brake tubes (3) between the master cylinder and the control module.
- the two brake tubes (4)
- the 3 nuts (5)
- the lower protective cover for the firewall.

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

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

Removing the power brake booster




Remove the pin for the power brake booster.

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





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

Installation

Installing the power brake booster

Note! For tightening torques, see: Tightening torque [1][2]Specifications.

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

Installing the brake pipes





Install:
- the two brake tubes (3)
- the lower protective cover for the firewall
- the 3 nuts (5)
- the two brake tubes (4).

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

Installing the heat deflector plate





Install:
- the heat deflector plate
- the hoses
- the clip.

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

Installing the protective covers





install:
- the protective cover for the firewall
- the plastic nut.





Install:
- the protective cover over the brake fluid reservoir
- the 2 clips.

Finishing


Install:
- the windshield wiper motor. See: Wiper mechanism, windshield Service and Repair.
- the battery box
- the 3 M6 screws
- the battery as shown: Battery Removal and Replacement.