Brake Booster, Removing And Installing: Installing

WARNING: This page is about a different car, the 2024 Audi A4 allroad. However, it is still accessible from the selected car via links, so may be relevant.

Install in the reverse order of removal while noting the following:

Do not move/transport the brake booster by the actuator rod.
Make sure that the actuator pin OVERVIEW - BRAKE BOOSTER/BRAKE MASTER CYLINDER => List Item:Actuator Pin for the brake lamp is pushed into the brake master cylinder. If this pin is missing, the brake lamp will not function.
Check the vacuum hoses for damage before the assembly and replace if necessary.

-- Check that the boot -2- has not slipped out of the surrounding groove -arrow- on the brake booster -1- as shown.

Courtesy of AUDI OF AMERICA, LLC

The boot -2- must rest securely in the groove all the way around -arrow-.

-- Install the brake booster with the master brake cylinder.

-- Install the bolts -arrows- and tighten to the required tightening specification OVERVIEW - BRAKE BOOSTER/BRAKE MASTER CYLINDER => List Item:Bolt.

Courtesy of AUDI OF AMERICA, LLC

-- Push the vacuum hose into the brake booster.

Courtesy of AUDI OF AMERICA, LLC

-- Install the Vacuum Sensor -G608- -item 2-. Refer to BRAKE BOOSTER PRESSURE SENSOR, REMOVING AND INSTALLING .

-- Slide the vacuum hose firmly onto the Vacuum Sensor -G608-.

Make sure the vacuum hose is connected at all of the separating points.

-- Connect the connector -1- for the Vacuum Sensor -G608- and connector -4- for the Brake Lamp Switch -F-.

CAUTION:

Risk of destroying the brake lines by bending.

- Never change the shape of the brake lines.

-- Insert the brake lines into the brake master cylinder by hand.

-- Tighten the union bolts -3- for the brake lines to the required tightening specification OVERVIEW - BRAKE BOOSTER/BRAKE MASTER CYLINDER => List Item:Brake Line and OVERVIEW - BRAKE BOOSTER/BRAKE MASTER CYLINDER => List Item:Brake Line.

-- Install the brake fluid reservoir. Refer to BRAKE FLUID RESERVOIR, REMOVING AND INSTALLING .

-- Install the plenum chamber bulkhead. Refer to PLENUM CHAMBER BULKHEAD, REMOVING AND INSTALLING .

-- Install the windshield wiper arms. Refer to WINDSHIELD WIPER ARMS, REMOVING AND INSTALLING .

-- Fill the brake fluid reservoir up to the "MIN" mark.

Fig 1: Brake Fluid Reservoir

Courtesy of AUDI OF AMERICA, LLC

-- Connect the brake pedal to the brake booster. Refer to BRAKE PEDAL, DISCONNECTING FROM BRAKE BOOSTER .

-- Remove all cloths from the vehicle that were previously placed down.

-- Bleed the brake system. Refer to HYDRAULIC SYSTEM, BLEEDING .

Make sure the brake lamp functions correctly.

CAUTION:

Faulty brakes increase the risk of an accident.

- Make sure the brakes are working correctly before driving the vehicle for the first time.