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

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

Fig 1: Identifying Brake Charger/Bleeder Unit VAS5234

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-- Place enough lint-free cloths in the engine area.

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

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.

-- If equipped, remove the instrument panel trim panel -1- in the driver footwell. Refer to VEHICLE INTERIOR TRIM PANELS .

Fig 2: Identifying Instrument Panel Trim Panel And, Bolts And Diagnostic Plug

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-- To do this, remove the bolts -arrows-.

-- Remove the diagnostic plug -2-.

-- Remove the footwell vent on the driver side. Refer to AIR DUCT .

-- If equipped, please remove the knee airbag. Refer to the appropriate service information .

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

-- Remove the noise insulation. Refer to NOISE INSULATION, REMOVING AND INSTALLING .

-- Remove engine cover near the -arrows-.

Fig 3: Engine Cover

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-- Observe the given sequence -1- through -4-.

-- Reach under the engine cover as far as possible.

CAUTION:

The bracket for attaching the engine cover to the cylinder head could break if removed incorrectly. Always remove the engine cover according to the following instruction.

-- Remove the heat shield -1- from the diesel particulate filter to do so remove the nuts -arrows-.

Fig 4: Locating Heat Shield Nuts

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-- Release and remove the bracket -1- from the toothed belt guard.

Fig 5: Identifying Particulate Filter Mount

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Vehicles with 2.0L diesel engines

Fig 6: Identifying Oil Pressure Connector, Bolt And Bracket

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-- Disconnect the connector -1- from the Oil Pressure Switch --.

-- Remove the bolt -2-.

-- Push the bracket -3- for the Differential Pressure Sensor -- in the -direction of the arrow- from the guide.

-- Move the bracket -3- with the lines still attached to the side.

-- Release and disconnect the connector -1-.

Fig 7: Identifying Connector, Fuel Lines, Bracket And Washer Fluid Hose

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-- Unclip the fuel lines -2- from the bracket -3-.

-- Unclip the washer fluid hose -4- from the bracket -3-.

-- Open the couplings -A- and -B- and remove the fuel lines. Disconnect the couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

Fig 8: Identifying Fuel Line Couplers

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WARNING:

The fuel line is under pressure.

Fuel poses a risk of injury to the eyes and skin.

Wear protective eyewear and protective clothing to avoid injury and contact with skin. Place a cleaning cloth around the connection point before loosening hose connections. Carefully open the connection point to release the pressure.

-- Move the fuel lines to the side.

-- Remove the bolts -arrows-.

Fig 9: Identifying Bolts

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-- Move the Auxiliary Fuel Pump -V393- or Fuel Pump 2 -V277- -1- with the lines still attached to the side.

Vehicles with 1.6L diesel engines

Fig 10: Identifying Fuel Line Couplers

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-- Open the couplings -A- and -B- and remove the fuel lines. Disconnect the couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

WARNING:

The fuel line is under pressure.

Fuel poses a risk of injury to the eyes and skin.

-- Unclip and free up the fuel lines.

-- Move the fuel lines to the side.

-- Disconnect and remove the connector -3- from the Differential Pressure Sensor -- -4-.

Fig 11: Identifying Connector And Differential Pressure Sensor

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-- Unclip the hoses -2- from the retainer.

-- Remove the bolts -1-.

-- Set the Differential Pressure Sensor -- -4- with lines attached to the side.

-- Move the fuel lines to the side.

-- Remove the bolts -arrows-.

Fig 12: Identifying Bolts

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-- Move the Auxiliary Fuel Pump -V393- or Fuel Pump 2 -V277- -1- with the lines still attached to the side.

Continuation for All Vehicles

Fig 13: Identifying Connector And Coolant Expansion Tank

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-- Release and remove the connector -1- from the coolant expansion tank -2-.

-- Unclip the wire -4- from the coolant expansion tank -2- and set aside.

-- Remove the bolts -3- and the coolant expansion tank -2-.

-- Move the coolant expansion tank upward and set aside.

-- Open the clips -arrows- and remove the upper toothed belt cover.

Fig 14: Removing Upper Toothed Belt Guard

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-- Release and remove the connectors -1- through -3-.

Fig 15: Disconnect The Black

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-- Guide the wires out of the brackets.

-- Remove the particulate filter bracket bolts -1-.

Fig 16: Identifying Particulate Filter Bracket Bolt

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-- Raise the vehicle.

-- Loosen the clamp -1- for the turbocharger/particulate filter connection and remove it.

Fig 17: Identifying Turbocharger/Particulate Filter Clamp

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NOTE:

The illustration above shows the bolt from the clamp -1- from below. This can also be installed in individual cases from above.

-- Disconnect the exhaust system. Refer to OVERVIEW - MUFFLER (CPLA, CPPA, CPKA, CPRA) or OVERVIEW - MUFFLER (DDSA, DDSB) .

-- Remove the exhaust system bracket from the subframe -arrows-.

Fig 18: Heat Shield Bolts

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-- Remove the bolts -1- and remove the drive axle cover -2-.

Fig 19: Identifying Bolts And Drive Axle Cover

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-- Remove the right drive axle form the flange, lay it down and secure it. Refer to the appropriate service information .

-- Remove the bolts -2- and -3- from the pendulum support.

Fig 20: Identifying Pendulum Support & Bolts

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-- Push the engine forward and support as shown.

Fig 21: Identifying Collar Bolt And 3253/5

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A - M10 x 35 Collar Bolt

3253/5 - Bearing Installer - Rear Wheel Bearing Kit: 3253

-- Remove the nuts -1-.

Fig 22: Identifying Nuts And Particulate Filter Bracket

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-- Remove the nuts -2- using the Wrench - Sw13: T10384 .

-- Remove bracket for particulate filter -3-.

-- Seal all openings using the Engine Bung Set: VAS6122 .

-- Lower the particulate filter just enough so that it touches the steering gear.

NOTE:

Pay attention to the Exhaust Gas Temperature Sensor -- and the Heated Oxygen Sensor -- when lowering onto the cables in order to avoid any damage.

-- Disconnect the connector -1- from the Brake Fluid Level Warning Switch -F34- -2-.

Fig 23: Identifying Connector And Brake Fluid Level Warning Switch

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-- Disconnect and remove the connector -A- from the Brake Lamp Switch -F-.

Fig 24: Identifying Connector And Brake Lamp Switch

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-- Remove the securing plate -arrows- and fold the noise insulation -1- forward.

Fig 25: Identifying Securing Plate And Noise Insulation

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Vehicles with Manual Transmission:

Fig 26: Identifying Supply Hose

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

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

-- Tie up the hose -2-.

-- Remove the brake lines -3- on the master brake cylinder -1-.

Fig 27: Identifying Brake Lines And Master Brake Cylinder

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CAUTION:

Brake lines must not be bent.

Do not confuse the brake lines when connecting them.

Mark the lines in their installed position before removing them.

-- Seal the brake lines with sealing plugs from the Repair Set.

-- Remove the nut -2-.

-- Pull the vacuum line -4- out of the brake booster -1-.

-- Remove the heat shield, if equipped.

-- Remove the nut -1-.

Fig 28: Identifying Connector And Brake Lamp Switch

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-- Carefully take the brake master cylinder -2- out of the brake booster.

-- Unclip the brake lines -1- from the bracket -2-.

Fig 29: Identifying Brake Lines, Bracket, Vacuum Line And Wiring Harness

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-- Unclip the vacuum line -3- from the bracket -2-.

-- Unclip the wiring harness -4- on the bulkhead -arrow-.

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

Fig 30: 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.