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

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

Fig 1: Identifying Instrument Panel Trim Panel And, Bolts And Diagnostic Plug

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-- Remove the instrument panel trim panel -1- in the driver footwell. Refer to VEHICLE INTERIOR TRIM PANELS .

-- 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, 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 .

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

Fig 2: Identifying Connector And Brake Fluid Level Warning Switch

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Vehicles with 1.4L gasoline engine, turbocharger and compressor:

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-- Remove the intake manifold -2- and the charge air hose -1-.

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

Fig 3: Identifying Connector And Brake Lamp Switch

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-- Place enough lint-free cloths in the area under the brake master cylinder.

-- Extract as much brake fluid as possible from the brake fluid reservoir with the Brake Charger/Bleeder Unit: VAS 5234 .

Fig 4: 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 waste disposal regulations.

-- Remove the locking plate -arrows- and remove the insulation -1- upward.

Fig 5: Identifying Securing Plate And Noise Insulation

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Vehicles with Manual Transmission:

Fig 6: 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-.

Further removal instructions for all vehicles:

Fig 7: Identifying Brake Lines And Master Brake Cylinder

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

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 8: 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 9: 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 10: 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.