Removing Brake Booster

Information 

The brake booster -1-  is removed together with the brake master cylinder -2-  and brake fluid reservoir -3-  .

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Removing brake booster with brake master cylinder and brake fluid reservoir

Information 

When carrying out work during which fluids can escape, leave electric plug connections to be disconnected locked and connected for as long as possible. This prevents fluid from getting onto electric contacts and causing corrosion.

Information 

Any escaping brake fluid must be removed immediately. Rinse contacts with water and dry them if necessary.

1. Place a cloth under the brake booster to soak up emerging brake fluid.
2. Extract the brake fluid from the brake fluid reservoir (e.g. with > VAS 6860 - brake filling and bleeding equipment)  .
   1. 2.1  Unscrew cap on the brake fluid reservoir and remove strainer.
3. On vehicles with manual transmission:  Disconnect vent line -2-  and return line -3-  from the brake fluid reservoir -1-  .

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   Lines on brake fluid reservoir

   1. 3.1  Close off vent line, return line and connection openings on the brake fluid reservoir using stoppers.
4. Remove brake lines -1-  from the brake master cylinder -2-  .

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   Brake lines on brake master cylinder

   1. 4.1  Unscrew cap screws -3-  and loosen brake lines from the bracket -4-  .
   2. 4.2  Close off brake lines and connection openings on the brake master cylinder using stoppers.
5. Release and disconnect electric plug connection -4-  for brake fluid reservoir -1-  .

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   Lines on brake fluid reservoir

6. Release and disconnect electric plug connections -1 and 2-  from brake booster -3-  .

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   Electric plug connections on brake booster

7. Disengage push rod -1-  from brake booster at the brake pedal.

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   Disengaging push rod from brake booster at the brake pedal

   1. 7.1  Guide > 9897 - release tool-2-  into mounting for push rod ball joint -Cut-out A-  .
   2. 7.2  Pull > 9897 - release tool-2-  to the rear at the grab handle -arrow B-  (retaining lugs -4-  open -arrows C-  )

      while pulling the brake pedal strongly to the rear -arrow D-  .

8. Detach brake booster -1-  from mounting saddle -2-  .

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   Mounting for brake booster on mounting saddle

   1. 8.1  Unscrew nuts -3-  .
   2. 8.2  Replace nuts.

      Information 

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      Brake booster

      • The brake booster must not be lifted in area -A-  .
      • Make sure not to damage the push rod boot -1- when removing and installing the brake booster. 
9. Carefully guide brake booster -1-  out of the plenum panel wall -arrow A-  .

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   Brake booster