Removal & Installation
NOTE:
Letters and numbers in parenthesis correspond to letters and numbers in illustrations.
- Open hood.
- Remove brake master cylinder. See BRAKE MASTER CYLINDER .
- Unplug Brake Assist System (BAS) release switch/solenoid valve electrical connector (A7/7x2). See Fig 1 .
- Unplug connector of BAS diaphragm travel sensor (A7/7x1).
- Remove clamp bolt (14) for jump starting point ground lead due to space limitations.
- Pull vacuum line (12) out of brake booster (A7/7). See Fig 2 .
- Remove control unit (C) due to space limitations. Place control unit to the side with lines and cables connected.
- Remove cover below instrument panel. See COVER BELOW INSTRUMENT PANEL .
- Remove brakelight switch (S9/1). Turn counter clockwise and pull out. See BRAKELIGHT SWITCH .
- Remove cotter pin (4) from retaining pin (3). See Fig 3 .
- Pull out mounting bolt.
- Remove nuts (13).
- Remove brake booster.
- Installation is the reverse of removal. During installation check brake booster (A7/7) and brake master cylinder (11) for damage and proper seating. Replace if necessary. Coat sealing surface with sealing compound. Install new self-locking nuts. Replace mounting bolt (3) if damaged or worn. Install a new cotter pin (4) into retaining pin. Check grommet holding vacuum line (12) for damage and replace if necessary. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS . Bleed brake system. See BLEEDING BRAKE SYSTEM . Check brake system for leaks. See TESTING FOR LEAKS USING PRESSURE GAUGE under TESTING.