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

Install in reverse order of removal while noting the following:

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

-- Using a Hot Air Gun: 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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- 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. .

-- 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  ) OVERVIEW - BRAKE BOOSTER/BRAKE MASTER CYLINDER, RHD - List Item: Seal.

-- Bleed the brake system. Refer to HYDRAULIC SYSTEM, STANDARD BLEEDING .

Vehicles with Manual Transmission: 

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

NOTE:

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

Fig 2: Identifying Brake Fluid Level Marks On Reservoir

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.