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Removing And Installing Brake Booster: Installation

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NOTE:
  • Basic setting of the push rod -dimension X-  is 138 mm (set in new brake boosters)! See Fig 1 . If necessary, correct during the relevant work!
Fig 1: Identifying Push Rod Setting Dimensions
G03103444Courtesy of PORSCHE OF NORTH AMERICA, INC.
  1. Insert the brake booster with bellows -B-  . See Fig 2 .
    Fig 2: Inserting Brake Booster With Bellows
    G03103445Courtesy of PORSCHE OF NORTH AMERICA, INC.
    NOTE:
    • Do not trap wiring harness!
  2. Tighten fastening screws (Torx T 45) -arrow-  to 23 Nm (17 ft.lb). See Fig 3 .
    Fig 3: Tightening Brake Booster Fastening Screws
    G03103446Courtesy of PORSCHE OF NORTH AMERICA, INC.
  3. Connect the 2 push rods. For this purpose, fit the retainer or fastening nut (standard fastening nut as of April 2001) -arrow-  . See Fig 4 .
    Fig 4: Installing Push Rod Fastening Nut
    G03103447Courtesy 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!
  4. Check the position of the brake pedal -Dimension X = 45 + 5 mm-  . Perform measurement between the center of the brake pedal plate and the accelerator pedal. Perform a fine adjustment of the brake pushrod if the correct position of the brake pedal is not given.
    Fig 5: Checking Brake Pedal Position
    G03103448Courtesy of PORSCHE OF NORTH AMERICA, INC.
    • Fine 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 6 . Subsequently re-tighten the lock nut.
    Fig 6: Adjusting Brake Pushrods
    G03103449Courtesy of PORSCHE OF NORTH AMERICA, INC.
  5. Fit the bellows onto the body or onto the connection sleeve and fasten with the clamps.
  6. Check the setting of the brake light switch -1-  . See Fig 7 .
    Fig 7: Locating Brake Light Switch
    G03103450Courtesy 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 .

  7. Fit the vacuum hose for the brake booster.
  8. Installing hydraulic unit and brake master cylinder. Fit all brake lines.
    NOTE:
    • Ensure that the reservoir is engaged correctly on the brake master cylinder.
  9. Bleed the brakes Serv. No. 47 01 07 (vehicle with and without TC) and Serv. No. 41 01 07 - vehicle with PSM.
    NOTE:
    • First bleed brakes as usual!
    • Only after this (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) or the booster pump control in the case of vehicles with PSM! If this is not observed, damage can occur to the return pump/booster pump!
      Fig 8: Identifying Porsche System Tester 2
      G03103451Courtesy of PORSCHE OF NORTH AMERICA, INC.
    • To bleed at rear on right with running return pump (TC) or at front right with running booster pump (PSM), the bleeding device remains connected (switched on)! Bleeding pressure approximately 2.0 bar!
  10. Bleed the clutch in manual transmission vehicles. Refer to BLEEDING THE CLUTCH SYSTEM . Bleed the clutch system.
  11. When replacing the hydraulic unit in vehicles with ABS/TC or PSM (4-channel system), code the control module (manual transmission or Tiptronic).
  12. Carry out the following tests:
    • Check the system (brake lines and connections) for leaks.
    • Read out and erase the fault memory of the ABS or PSM 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 and if necessary also the PSM-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 or PSM fault memory again. There must not be any stored faults.
  13. Fit covers -A/B-  and spare wheel. See Fig 9 .
Fig 9: Fitting Covers
G03103452Courtesy of PORSCHE OF NORTH AMERICA, INC.
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