Brake Booster, Removing And Installing, Electromechanical Brake Booster: Installing

WARNING: This page is about a different car, the 2024 Audi S6 and 2024 Audi A6 Quattro. 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:

CAUTION:

Deformation increases the risk of damage.

- Do not hold the brake booster on the actuator rod.

Do not let any brake fluid run into the brake booster.

CAUTION:

Risk of overheating the brakes due to the incorrect positioning of the actuator rod.

- Before installing the brake booster, measure the length of the actuator rod.

-- Adjust the actuator rod length with the ball head to the correct dimension. Refer to Figure.

-- Before installing the brake booster thoroughly clean the contact surface on the brake booster and the bulkhead.

CAUTION:

Installing the brake booster incorrectly increases the risk of malfunctions.

- Check the contact surface on the bulkhead. It must be flat and not deformed.

- Check the contact surface on the brake booster. It must be flat and not deformed.

If deformed, service the bulkhead or replace the brake booster.

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

After inserting the in the vehicle the brake booster must be flat and completely on the new seal.

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 -arrows- for the brake lines to the required tightening specification -item 1- OVERVIEW - BRAKE BOOSTER/BRAKE MASTER CYLINDER, ELECTROMECHANICAL BRAKE BOOSTER => List Item:Brake Line, -item 2- OVERVIEW - BRAKE BOOSTER/BRAKE MASTER CYLINDER, ELECTROMECHANICAL BRAKE BOOSTER => List Item:Brake Line and -item 17- OVERVIEW - BRAKE BOOSTER/BRAKE MASTER CYLINDER, ELECTROMECHANICAL BRAKE BOOSTER => List Item:Brake Line.

Courtesy of AUDI OF AMERICA, LLC

-- Install the windshield wiper motor. Refer to WINDSHIELD WIPER MOTOR V, REMOVING AND INSTALLING .

-- 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 .

-- 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 .

-- After removing and installing the same brake booster, select the "Brake booster basic setting" program. Refer to DIAGNOSTIC ENTRIES .

-- After replacing the brake booster, complete the "Control module, replacing" program using the Vehicle Dianostic Tool.

CAUTION:

Faulty brakes increase the risk of an accident.

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