Brake Booster, Removing And Installing, LHD With 5-Cylinder Gasoline Engine: Removing

WARNING: This page is about a different variant/trim than selected.

Fig 1: Disconnecting Connector And Intake Hose

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-- Open the clamp -2- and disconnect the intake hose.

-- If equipped, disconnect the connector -1- and remove.

-- Remove the bolts -3- and the intake hose.

-- Pull the engine with a jerk out of the fasteners first at the front -arrow 1-, then at the right rear -arrow 2- and finally at the left rear -arrow 3-.

Fig 2: Identifying Removal Of Engine Cover With Jerk Out Of Mount First

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-- Carefully swivel the engine cover out of rear area.

-- Release and remove hoses -arrows- on the intake hose.

Fig 3: Identifying Intake Hose And Throttle Valve Unit

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NOTE:

Some vehicles are equipped with 1 or 2 connectors on the intake hose.

-- Remove the intake hose from the Throttle Valve Control Module -J338-.

-- If equipped, release and remove the connectors -arrows-.

Fig 4: Identifying Vent Pipe

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-- If equipped, release and remove the vent pipe -1- on the Secondary Air Injection Solenoid Valve -N112-.

-- If equipped, open the retainer -3- and move the vent pipe to the side.

-- Remove the vacuum line -1- from the brake booster -2-.

Fig 5: Identifying Vacuum Hose

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-- If equipped, remove the vacuum hose -2-.

Fig 6: Disconnecting Vacuum Hose

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-- Open the bracket -arrow- and free up the vacuum line -1-.

-- Pull the vacuum line -1- off the vacuum pump and then remove the vacuum line -1-.

Vehicles with Automatic Transmission

Fig 7: Identifying Bolts -1 And 6-, Connector -2-, Transmission Control Module -3- And Bracket -7-

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-- Release the retaining tab and remove the Transmission Control Module -J217- from the bracket.

-- Unclip the wiring harness on the bracket and move the Transmission Control Module -J217- to the side.

-- Remove the bolts -1- and -6-.

Vehicles with Power Steering

-- Remove the bolts -1- and -6-.

-- Move the bracket -7- with the power steering fluid reservoir to the side.

Continuation for All Vehicles

NOTE:

The battery ground cable must be disconnected for the following procedure. For this reason, check if a coded radio is installed. If necessary, obtain anti-theft code beforehand.

-- Remove the battery and the battery tray. Refer to OVERVIEW - BATTERY .

Fig 8: Identifying Battery Housing Bolts

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-- Remove the bolts -arrows-.

CAUTION:

Danger of causing damage to electronic components when disconnecting the battery.

Follow the steps for disconnecting the battery.

-- Place enough lint-free cloths near the engine and transmission.

-- Extract as much brake fluid as possible from the brake fluid reservoir using Brake Charger/Bleeder Unit: VAS5234 .

Fig 9: Identifying Brake Charger/Bleeder Unit VAS5234

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WARNING:

Brake fluid must never come into contact with fluids containing mineral oils (oil, gas, cleaning solutions). Mineral oils damage the brake system plugs and boots.
Brake fluid is poisonous, and must never be siphoned by mouth under any circumstances. Also due to its corrosive effect, brake fluid must not come into contact with paintwork.
Extracted brake fluid cannot be used again.
Follow all disposal regulations.

Vehicles with Automatic Transmission

-- Remove the noise insulation or impact guard. Refer to OVERVIEW - NOISE INSULATION .

-- Remove the selector lever cable from the transmission. Refer to OVERVIEW - SELECTOR MECHANISM .

-- Move the selector lever into >>P<<.

Fig 10: Identifying Cable Disengaged And Removed From Mounting Bracket

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-- To remove the selector lever cable from the transmission, first release the cable -1- and then remove it from the cable bracket -2-.

NOTE:

Do not use pliers, otherwise the tabs on the cable could break off.

Do not bend or kink the selector lever cable.

-- Pry out the cable -1- from the lever -3- with an open end wrench -2-.

Fig 11: Identifying Selector Lever Cable, Lever/Selector Shaft And 10 mm Open-End Wrench

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-- Remove the selector lever cable bracket from the transmission.

Fig 12: Identifying Selector Lever Cable Retainer And Bolts

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-- Position the Hose Clamps - Up To 25mm: 3094 on the coolant hoses and close them.

Fig 13: Hose Clamps Position On ATF Cooler Hoses

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-- Remove the coolant hoses from the ATF cooler.

Continuation for All Vehicles

Fig 14: Identifying Spring Clamps And Radiator Coolant Hoses

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-- Position the Hose Clamps - Up To 25mm: 3094 on the coolant hoses -arrows- and close them.

-- Remove the coolant hoses -arrows- from the heater core.

-- Move the coolant hoses to the side.

-- Remove the star-shaped washers -arrows-.

Fig 15: Removing Brake Master Cylinder

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-- Release and remove the connector.

-- Unclip the connector and wiring harness from the bulkhead.

-- Fold the bulkhead damper -1- forward in -direction of the arrow- and guide it out.

NOTE:

It is not necessary to remove the insulation.

Vehicles with Manual Transmission

-- Remove the supply hose -2- for the clutch master cylinder -3- from the brake fluid reservoir -4-.

Fig 16: Identifying Supply Hose

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-- Seal the hose -2- for the clutch master cylinder -3- with the Engine Bung Set: VAS6122 -1-.

-- Tie up the hose -2-.

-- Remove the selector mechanism from the transmission. Refer OVERVIEW - SELECTOR MECHANISM to .

-- Remove the bracket from the selector mechanism on the transmission. Refer to OVERVIEW - SELECTOR MECHANISM .

NOTE:

It is necessary to separate the cable retainer from the selector cable prior to removal to prevent damaging the selector cable.

Continuation for All Vehicles

CAUTION:

Brake lines must not be bent.

Do not confuse brake lines when connecting them.

Mark the lines in their installed position before removing them.

-- Disconnect and remove the connector -1- from the Brake Fluid Level Warning Switch -F34-.

Fig 17: Identifying Connector & Warning Switch

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-- Remove the brake line pipe fitting -2-.

-- Seal off the brake line with the Plug.

-- Remove the fastening pin -2- in the -direction of the arrow-.

Fig 18: Identifying Brake Fluid Reservoir

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-- Carefully pull the brake fluid reservoir -1- out of the plugs.

-- Unlock and disconnect the connector -1- from the Brake Lamp Switch -F- -2-.

Fig 19: Identifying Brake Line Tube Fitting

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-- Unclip the wiring bracket from the brake master cylinder.

-- Remove the brake line tube fitting -2- from the brake master cylinder -1-.

Fig 20: Identifying Master Brake Cylinder

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-- Seal off the brake line with the Plug.

-- Unscrew the threaded connection -arrows- on the brake master cylinder -1-.

-- Carefully take the brake master cylinder out of the brake booster.

-- Disconnect the brake pedal from the brake booster. Refer to BRAKE PEDAL, DISCONNECTING FROM BRAKE BOOSTER .

-- Remove the threaded connection -1- from the brake booster on the pedal bracket.

Fig 21: Locating Pedal Bracket Nuts

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NOTE:

It is not necessary to loosen the threaded connection -2-.

-- Carefully remove the brake booster from the vehicle.