Installing Brake Booster

→ After fitting the brake master cylinder or the hydraulic unit, calibrate the pressure sensor using PIWIS Tester II 9818  .

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

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

Information 

• 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 →  Tightening Torques   . 

1. Carefully pull the brake lines of the brake master cylinder and left front wheel forward and press the air-conditioning lines downward.
2. Carefully insert the brake booster -direction arrow-  .
   Fig 1: Inserting Brake Booster

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3. Guide the → Fig 2 pushrod of the brake booster through the opening in the passenger compartment. Ensure the boot is seated correctly.
   Fig 2: Identifying Pushrod Of Brake Booster

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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.
6. Fit the holder for the stop light switch and connect the connector -arrow-  .
   Fig 3: Locating Stop Light Switch Connector

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7. Fit the cover on the driver's side → Installing front trim (engine compartment) .
8. Fit the clamps of the air-conditioning lines.

   Information 

   • 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).
   Fig 4: Locating Relay Carrier

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

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11. Join the brake line in the front left wheel housing (remove sealing plugs).
    Fig 6: Locating Brake Line

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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 → Removing The Brake Master Cylinder  .
17. Fit left plenum panel partition.