Brake Booster, With 5-Cylinder Gasoline Engine: Installing

WARNING: This page is about a different car, the 2016 Volkswagen Beetle, 2015 Volkswagen Beetle, 2014 Volkswagen Beetle, and 2013 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

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 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 [For transmission(s) 0A4] Diagnosis and Testing or [For transmission(s) 02Q] [For engine(s) CVCA, CPLA, CJAA, CPPA, CCTA, CBFA] Diagnosis and Testing .

Vehicles with Automatic Transmission

Fig 2: Identifying Selector Lever Cable Retainer And Bolts

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-- The selector lever cable bracket must not touch the ATF cooler.

Continuation For All Vehicles

Fig 3: 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, CPKA, CPLA, CJAA, CBUA, CPPA, CCTA, CBFA] Removal and Installation .

-- Check the coolant level. Refer to [For transmission(s) 02E, 02Q] [For engine(s) CVCA, CJAA] Diagnosis and Testing or [For engine(s) CPRA, CPKA, CPLA, CPPA] Diagnosis and Testing or [For engine(s) CCTA, CBFA] Diagnosis and Testing or [For engine(s) CBUA] Diagnosis and Testing or [For engine(s) CVCA] Diagnosis and Testing .

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

Fig 4: Identifying Correct Installation Of Rubber Insulators

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CAUTION: Make sure the 4 fasteners (ball sockets) are positioned correctly before installing the engine cover. Move them into their correct position, if necessary. Otherwise the engine cover will be damaged.

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

Fig 5: Identifying Brake Fluid Level Marks On Reservoir

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