Brake Booster, Removing And Installing, With 4-Cylinder Diesel Engine: Installing
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 bonding 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.
Install in reverse order of removal. Note the following:
-- Carefully install the brake booster and tighten the nuts hand-tight.
-- 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 brake master cylinder to the brake booster.
-- 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. .
Follow the Tightening Sequence:
-- Tighten nuts -1 through 4- in the sequence shown in the illustration above.
Coat the plugs with brake fluid before pressing the brake fluid reservoir into the brake master cylinder.
-- 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
-- Insert the tab on the vacuum line -1- into the opening -arrow- in the brake booster -2-.
-- Install and connect the battery. Refer to BATTERY, REMOVING AND INSTALLING .
-- Make sure the rubber buffers fit correctly in the mounts when installing the engine cover.
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.