Installing Brake Booster

Information 

• When fitting the brake booster -1-  , make sure not to damage the seal -3- and the boot -4- on the push rod -2-  .
• Check retaining lugs for the push rod through the opening in the plenum panel for signs of damage  .

  Brake booster (example) 

1. Fit the brake booster into the vehicle. Check that the boot is seated correctly when doing so.
2. Tighten fastening screws -1-  securing the brake booster -3-  to the mounting saddle. Tightening torque 25 Nm (19 ftlb.) 

   Brake booster mounting 

3. Fit brake lines -2-  on the brake master cylinder.

   Brake lines on brake master cylinder 

   1. 3.1. Remove stoppers from brake lines and brake master cylinder.
   2. 3.2. Fit brake lines on the brake master cylinder.
   3. 3.3. Tighten union nuts.

      Brake lines to brake master cylinder (left-hand drive vehicles): Tightening torque 14 Nm (10.5 ftlb.) 

      Brake lines to brake master cylinder (right-hand drive vehicles): Tightening torque 18 Nm (13 ftlb.) 

4. Plug in connector -2- on the brake fluid reservoir.

   Connector on brake fluid reservoir 

   Information 

   Damage when installing a new brake booster:

   • Before connecting the brake pedal to the brake booster, the stopper at the vacuum line connection must be removed.
   • If this is not done, there is a risk of damage to the brake booster.
5. Connect brake pedal to the brake booster.

   Fitting push rod (example) 

   1. 5.1. Position brake pedal on the push rod for the brake booster.
   2. 5.2. Press the brake pedal fully until the push rod -2-  engages with an audible click in the retaining lugs -1-  on the brake pedal.
   3. 5.3. Check that the push rod -2-  is fully engaged in the retaining lugs -1-  .