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Removing And Installing Brake Booster: Fitting

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CAUTION: Material damage to the connection to the brake pedal if the tightening torque used on the connecting pin is too great!
  • It is essential to observe the specified tightening torque on the connection thread bushing/pin!
  1. Install new brake pushrod -9.1-  . Tighten the threaded bushing arrow  of the pin to 10 Nm (7.5 ft.lb.) See Fig 1 .
    Fig 1: Installing Brake Pushrod
    G03103462Courtesy of PORSCHE OF NORTH AMERICA, INC.
  2. Insert seal -7.2-  (without lubricant) into the firewall. It is essential to ensure correct seating! Then insert (push in) the connection sleeve -7.1-  into the seal -7.2-  using rubber sliding compound for example Capella or tyre mounting paste. Recheck that it is seated correctly and correct if necessary. See Fig 2 .
    Fig 2: Inserting Seal Into The Firewall (Without Lubricant)
    G03103463Courtesy of PORSCHE OF NORTH AMERICA, INC.
  3. Mount seal -7.3-  and coat with Capella or tyre mounting paste. See Fig 2 .
  4. Mount intermediate piece -11-  (2 M8 nuts and hexagon socket head bolt). Tightening torque of the 2 M8 nuts = 23 Nm (17 ft.lb) See Fig 3 .
    Fig 3: Mounting Intermediate Piece
    G03103464Courtesy of PORSCHE OF NORTH AMERICA, INC.
  5. Install battery.
  6. Install new pushrod (if not already present) -12.1-  in place of -12-  . See Fig 4 . When doing so, observe installation dimension X (138 mm).
    Fig 4: Installing New Pushrod
    G03103465Courtesy of PORSCHE OF NORTH AMERICA, INC.

    Basic setting of the push rod -dimension X-  is 138 mm (set in new brake boosters). See Fig 5 . If necessary, correct during the relevant work!

    Fig 5: Identifying Pushrod Setting Dimension X
    G03103466Courtesy of PORSCHE OF NORTH AMERICA, INC.
  7. Install brake booster and brake master cylinder with mounted bellows -B-  and tightened clamps -6-  . See Fig 6 .
    NOTE:
    • Before using the brake booster, push the screw clamp -6.1- onto the bellows -B-  or onto the brake pushrod! See Fig 6 .
      • Fig 6: Pushing The Screw Clamp 6.1 Onto The Bellows -B-
      G03103467Courtesy of PORSCHE OF NORTH AMERICA, INC.
  8. Tighten fastening screws of brake booster (Torx T 45) -arrow-  to 23 Nm (17 ft.lb). Fit the vacuum line for the brake booster.
    Fig 7: Tightening Fastening Screws Of Brake Booster
    G03103468Courtesy of PORSCHE OF NORTH AMERICA, INC.
    • If the brake master cylinder has been removed, tighten the fastening nuts (M14) to 49 Nm (36 ft.lb.).
  9. Connect the 2 push rods. To do so, mount the fastening nuts -arrow-  . See Fig 8 .
    Fig 8: Connecting Pushrod With Fastening Nuts
    G03103469Courtesy of PORSCHE OF NORTH AMERICA, INC.
    NOTE:
    • Adjusting the brake pushrod length changes the position of the brake pedal.
    • Perform a fine adjustment of the brake pushrod if the correct position of the brake pedal is not given!
    • After the brake pushrod is adjusted, check the brake light switch adjustment!
  10. Check the position of the brake pedal -Dimension X = 45 + 5 mm-  . See Fig 9 . Perform measurement between the Centre of the brake pedal plate and the accelerator. Perform a fine adjustment of the brake pushrod if the correct position of the brake pedal is not given.
    Fig 9: Identifying Brake Pedal Position X
    G03103470Courtesy of PORSCHE OF NORTH AMERICA, INC.
    • Precise adjustment of brake pushrods: Undo the lock nut for this purpose and the turn the push rod accordingly at the hexagon -arrow-  until -dimension X = 45 + 5 mm-  has been achieved. See Fig 9 . Subsequently re-tighten the lock nut.
    Fig 10: Adjusting Brake Pushrods
    G03103471Courtesy of PORSCHE OF NORTH AMERICA, INC.
  11. Check the setting of the brake light switch -1-  . SeeFig 11 .
    Fig 11: Locating Brake Light Switch
    G03103472Courtesy of PORSCHE OF NORTH AMERICA, INC.

    The pedal must move a perceptible distance of approx. 5 to 10 mm before the brake light lights up. At the same time, check (make sure) that the brake light lights up before the pedal meets perceptible resistance or before brake pressure builds up. If necessary, set/re-adjust. Refer to BRAKE LIGHT SWITCH SETTING .

  12. Fit the bellows -B-  to the connection sleeve -7.1-  and secure with the screw clamp -arrow-  . See Fig 12 .
    Fig 12: Connecting Bellows To Connection Sleeve
    G03103473Courtesy of PORSCHE OF NORTH AMERICA, INC.
  13. If necessary, fit the alarm horn to the intermediate piece and clip in the air-conditioning line.
  14. Install hydraulic unit.
  15. Bleed brake Serv. No. 47 01 07 (vehicle with and without TC).
    NOTE:
    • First bleed brakes as usual!
    • Only after the conventional bleeding should the return pump actuation be performed (continue bleeding) with the Porsche System Tester 2 in vehicles with TC (Traction Control)! If this is not observed, damage can occur to the return pump/booster pump!
    • To bleed at rear on right with running return pump motor (TC), the bleeding device should remain connected and switched on! Bleeding pressure approximately 2.0 bar!
    Fig 13: Locating Diagnostic Socket
    G03103474Courtesy of PORSCHE OF NORTH AMERICA, INC.
  16. Bleed the clutch in manual transmission vehicles. Refer to BLEEDING THE CLUTCH SYSTEM . Bleed the clutch system.
  17. When replacing the hydraulic unit in vehicles with ABS/TC (4-channel system), code the control module (manual transmission or Tiptronic).
  18. Carry out the following tests:
    • Check the system (brake lines and connections) for leaks.
    • Read out and erase the fault memory of the ABS control module with the Porsche System Tester 2 (PST 2). Additionally, perform the static test in the system.
    • Check electrical and hydraulic lines (brake lines) for incorrect assignment using the PST 2.
    NOTE:
    • The exchange test checks that the brake lines/solenoid valves are assigned to the correct brake calipers (wheels)!
    • Then start the engine. The ABS or ABS/TC related lights in the instrument cluster must go out when the engine is running.
    • Carry out a function check of the brakes. Then perform a short test drive and perform at least one ABS control operation, taking the road conditions into consideration. Read out the ABS fault memory again. There must not be any stored faults.
  19. Perform the work which is necessary due to disconnecting the battery. WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY .
  20. Fit cover -A/B-  and spare wheel. See Fig 14 .
Fig 14: Fitting Covers
G03103475Courtesy of PORSCHE OF NORTH AMERICA, INC.
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