Brake Booster, Removing And Installing, RHD With 4-Cylinder Diesel Engine: Installing

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

Install in reverse order of removal. Note the following:

NOTE:

The brake booster is also bonded with the seal at the factory only.

The new seal between the brake booster and bulkhead must not be bonded.

-- Remove any bonded joint residue from the brake booster and the bulkhead.

-- Using a : VAG1416 , warm the adhesive residue at a low setting and remove it.

-- Clean the surfaces thoroughly.

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

Fig 1: Brake Booster Tightening Sequence

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-- Tighten the nuts -1 through 4- in the sequence shown.

-- When assembling the brake master cylinder with the brake booster, make sure that the pushrod is correctly seated in the brake master cylinder.

-- Make sure the seal fits correctly when attaching the master brake cylinder to the brake booster -item ) OVERVIEW - BRAKE BOOSTER/BRAKE MASTER CYLINDER, RHD - List Item: Seal.

-- Clip the brake pedal to the brake booster. Refer to BRAKE PEDAL, ATTACHING TO BRAKE BOOSTER - Hold the pushrod ball head in front of the mount and push the brake pedal toward the brake booster so that the ball head engages audibly. .

-- Bleed the brake system. Refer to HYDRAULIC SYSTEM .

Vehicles with Manual Transmission:

-- Bleed the clutch. Refer to the appropriate service information .

Continuation for All Vehicles:

Fig 2: Identifying Vacuum Hose

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

NOTE:

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

Fig 3: Identifying Brake Fluid Level Marks On Reservoir

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-- 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 four fasteners (ball sockets) are positioned correctly before installing the engine cover. Move them back into their position, if necessary. Otherwise it could cause damage to the engine cover.