Installing Brake Booster

Information 

Damage when installing a new brake booster: 

If the brake booster was replaced, the stopper at the vacuum line connection must be removed before connecting the brake pedal to the brake booster.

If this is not done, there is a risk of damage to the brake booster.

Information 

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Brake booster (example)

• 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. 

Information 

The brake booster must not be handled in the push rod/bellows area.

1. Install brake booster -1-  .

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   Screws for brake booster

   1. 1.1 Move brake booster -1-  into installation position and check that the boot is fitted correctly.
   2. 1.2 Fit and tighten screws -2-  .

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2. Connect and lock cable plug -1-  .

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   Cable plug

   Information 

   Fit the vacuum line before connecting the brake booster and brake pedal.

3. Connect vacuum connection -1-  to the brake booster -2-  .

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   Vacuum line and cable plug

   Information 

   Always replace brake boosters on which the push rod has pushed past the brake pedal clip and the screws have been tightened to their final tightening torque.

4. Connect brake booster push rod -2-  to brake pedal -1-  .

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   Brake booster push rod on brake pedal

   1. 4.1 Fasten brake booster push rod -2-  to the ball joint mounting -3-  .
   2. 4.2 Press brake pedal -1-  towards the brake booster -arrow A-  with your hand until the push rod -2-  engages securely in the retaining lugs of the ball joint mounting.

   Information 

   Do not remove the stoppers until immediately before guiding on the brake pressure lines.

   Information 

   Make sure not to get the brake lines mixed up.

5. Connect brake lines -1-  to brake master cylinder -2-  .

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   Brake lines to brake master cylinder (left-hand drive vehicles)

   1. 5.1 Connect brake lines -1-  to brake master cylinder -2-  .
   2. 5.2 Screw in and tighten union nuts on brake lines -3- 

      Left-hand drive:> 

      Right-hand drive:> 

6. Secure vacuum lines -1-  to plastic bracket -2-  .

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   Vacuum lines on plastic bracket

   1. 6.1 Install plastic bracket -2-  .
   2. 6.2 Clip vacuum lines -1-  into plastic bracket -2-  .
   3. 6.3 Connect quick connectors -4 and 5-  until they engage securely.
   4. 6.4 Clip in clip -3-  .