BOOSTER, Power Brake: Installation: Booster

NOTE: Make sure there is a NEW booster seal placed over push rod and mounting studs on rear of booster prior to installation. Failure to do so may result in a leak and possible premature failure of the brake booster.

Fig 1: BOOSTER SEAL

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Install a NEW booster seal (2) over push rod and mounting studs on rear of booster (1).

Fig 2: BOOSTER AND PEDAL MOUNTING
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Install power brake booster through opening between cross-brace and windshield. Guide booster (1) push rod and mounting studs through dash panel (2).
NOTE: Be sure to tighten all four booster mounting nuts to specifications or a vacuum leak can result.
Install four power brake booster mounting nuts (4). Tighten nuts to 25 N.m (18 ft. lbs.) torque.

Fig 3: BRAKE LAMP SWITCH AND PEDAL ROD
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Slide booster push rod (5) onto brake pedal pin (4). Install NEW retaining clip (3) securing push rod to brake pedal.
Install and adjust brake lamp switch (2). Refer to Electrical - Lamps and Lighting/Lamps/Lighting - Exterior/SWITCH, Stop Lamp - Installation .

Fig 4: VACUUM HOSE CONNECTION
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Connect vacuum hose (3) to check valve (2) on face of booster (1). Do not remove check valve from booster.

Fig 5: ESP WIRING CONNECTIONS AT BOOSTER AND MASTER
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If equipped with MK25 and Electronic Stability Program (ESP), connect wiring harness (6) connector at pedal travel sensor (7) on power brake booster (3).
If equipped with MK25 and ESP, connect wiring harness (6) connector at active brake booster solenoid (4).
Install master cylinder (1). See Brakes/Hydraulic/Mechanical/MASTER CYLINDER, Brake - Installation .
Install windshield wiper module. Refer to Electrical - Wipers/Washers/Wipers/Washers/LINKAGE, Wiper Arm - Installation .

Fig 6: BATTERY AND CABLES
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Connect negative battery cable (2).
Fill and bleed brakes as necessary. See Brakes - Standard Procedure .