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Home >> Porsche >> 2006 >> Cayenne Base, Automatic >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Brakes - Hydraulics, Regulator, Booster >> 47 70 19 Removing and installing brake booster - as of MY 2003 (All Models Except Cayenne S TIO Titan) >> Installing brake booster

Installing brake booster

WARNING: Porsche Stability Management does not work without values for the current brake pressure. 
  • Danger of personal injury and material damage when the hydraulic unit is not calibrated. 

→ After assembly of the brake master cylinder or hydraulic unit, the pressure sensor must be calibrated with the Porsche System Tester.

→ To do this, calibrate the pressure sensor in the menu >> PSM >> Calibration >> Pressure sensor <<.

→ The security code is stored under menu >> PSM >> Actual values >> Security code <<. The code is entered in the last four positions.

NOTE:
  • Absolute cleanliness is necessary when installing the brake booster as well as the adjacent brake master cylinder. Dirt can cause faults in the system. 
  • Calibrate the vehicle with the Porsche System Tester. 
  • Bleed the vehicle according to the plan to ensure full operation of the brake system. 
  • When inserting the brake booster, make sure the brake pushrod and boot are guided correctly. 
  • Pay attention to tightening torques →  47 TW Tightening torques for brake hydraulics - as of MY 2003 (All Models Except Cayenne S TIO Titan)   .

1. Carefully pull the brake lines of the brake master cylinder and left front wheel forward and press the air-conditioning lines downward.

Fig 1: Insert brake booster
GP00010590Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Carefully insert the brake booster -direction arrow-  . See Fig 1.

Fig 2: Brake booster pushrod
GP00010591Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Guide the pushrod of the brake booster through the opening in the passenger compartment. Ensure the boot is seated correctly. See Fig 2.

4. Fit the brake booster with four M8 fastening nuts.

5. Press the brake pedal forward until the ball socket engages in the mounting point.

Fig 3: Stop light switch connector and holder
GP00017846Courtesy of PORSCHE OF NORTH AMERICA, INC.

6. Fit the holder for the stop light switch and connect the connector -arrow-  . Refer to 94 36 19 Removing and installing brake light switch - as of MY 2003 (All Models) . See Fig 3.

7. Fit the cover on the driver's side. Refer to 70 02 19 Removing and installing front cover (engine compartment) - as of MY 2003 (All Models) .

8. Fit the clamps of the air-conditioning lines.

Fig 4: Relay carrier
GP00018475Courtesy of PORSCHE OF NORTH AMERICA, INC.
NOTE:
  • If the rubber bushes stick to the holders in the plenum panel when removing the relay carrier, these must be fitted in the openings provided before being inserted again. 

9. Install relay carrier in the plenum panel. To do this, fit the six connectors in the rear section of the relay carrier ( -arrow-  and right marking). See Fig 4.

Fig 5: Location of M6 screws on lower closing panel
GP00010593Courtesy of PORSCHE OF NORTH AMERICA, INC.

10. Join the closing panel using the two M6 screws -arrows-  (shown here when fitting the brake booster - relay carrier removed). See Fig 5.

Fig 6: Front left wheel housing brake line
GP00010595Courtesy of PORSCHE OF NORTH AMERICA, INC.

11. Join the brake line in the front left wheel housing (remove sealing plugs).

12. Install front left wheel housing liner.

13. Clip the brake line to left front wheel in the bracket underneath the relay carrier in the plenum panel.

14. Connect the plug on the distance sensor of the brake booster.

15. Connect vacuum pipe to the brake booster.

16. Fit brake master cylinder → 471519 Removing and installing brake master cylinder - chapter on "installing" .

17. Fit left plenum panel partition.

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