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Brake Booster: Removal

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2003 BMW M5, 2003 BMW 540i, 2003 BMW 530i, 2003 BMW 525i, and 2002 BMW M5. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove master cylinder. See MASTER CYLINDER .
  2. Remove left windshield wiper arm.
  3. Move hood lid into assembly position.
  4. Pull off rubber seal (1). Remove securing clamps of cowl cover (2) up to middle of windshield. Pull cover upwards and away. See Fig 1.
  5. Release screws and remove cowl cover. See Fig 2.
  6. Remove cover (1) behind booster. Remove line feed-through (2). Pull vacuum hose (3) off of brake unit. See Fig 3.
  7. Remove brake light switch. See BRAKE LIGHT SWITCH .
  8. Pull off retainer (1). Unhinge recoil spring (2). See Fig 4.
  9. Withdraw pin (3). See Fig 5.
  10. Loosen pedal assembly nuts (1) and bolts (2). See Fig 6.
  11. Pull pedal assembly slightly away from bulkhead.
    12. CAUTION: Do not use any force when removing and installing brake booster unit. Unit can be damaged under certain circumstances.
  12. Carefully swing out brake unit and remove from bulkhead.
Fig 1: Removing Rubber Seal & Securing Clamps
G00103308Courtesy of BMW OF NORTH AMERICA, INC.
Fig 2: Locating Cover Screws
G00103309Courtesy of BMW OF NORTH AMERICA, INC.
Fig 3: Removing Booster Components
G00103310Courtesy of BMW OF NORTH AMERICA, INC.
Fig 4: Locating Retainer & Recoil Spring
G00103311Courtesy of BMW OF NORTH AMERICA, INC.
Fig 5: Locating Pin
G00103312Courtesy of BMW OF NORTH AMERICA, INC.
Fig 6: Locating Pedal Assembly Nuts & Bolts
G00103313Courtesy of BMW OF NORTH AMERICA, INC.
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