Brake Booster, With 4-Cylinder Diesel Engine: Installing

Install in reverse order of removal. Note the following:

-- Carefully install the brake booster and tighten the nuts hand-tight.

-- When installing together the brake master cylinder and brake booster, make sure that the push rod is correctly located in the brake master cylinder.

-- Make sure the seal fits correctly when attaching the master brake cylinder to the brake booster.

-- Clip the brake pedal to the brake booster. Refer to BRAKE PEDAL, ATTACHING TO BRAKE BOOSTER => Hold the push rod ball head in front of the mount and push the brake pedal toward the brake booster until the ball head engages audibly. .

Follow the Tightening Sequence:

Fig 1: Locating Pedal Bracket Nuts

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-- Tighten bolts -1- through -4- in the same sequence as shown.

Coat the plugs with brake fluid before pushing the brake fluid reservoir into the master brake cylinder.

-- Bleed the brake system. Refer to DESCRIPTION AND OPERATION .

Vehicles with a Manual Transmission 

-- Bleed the clutch. Refer to CLUTCH SYSTEM, BLEEDING .

Continuation For All Vehicles 

Fig 2: Identifying Vacuum Hose

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-- Insert the tab on the vacuum line -1- into the opening -arrow- in the brake booster -2-.

-- Install and connect the battery. Refer to [For transmission(s) 0A4, 02E, 09G, 02Q] [For engine(s) CVCA, CPRA, CBTA, CPKA, CPLA, CJAA, CBUA, CPPA, CCTA, CBFA] Removal and Installation .

-- Make sure the rubber buffers fit correctly in the mounts when installing the engine cover.

Fig 3: Identifying Correct Installation Of Rubber Insulators

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NOTE: To prevent the brake fluid from overflowing from the reservoir, the level must not be over the MAX mark -1-.

Fig 4: Identifying Brake Fluid Level Marks On Reservoir

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