Brake Booster, Removing And Installing, LHD Vehicles

Special tools and workshop equipment required 

• Hot air gun, for example Wiring Harness Repair Set - Hot Air Blower:VAS 1978/14A  .
  Fig 1: Hot Air Blower VAG1416

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Component Location Overview. Refer to Fig 2.

Fig 2: ABS Layout, LHD:

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Removing

-- Remove the main brake cylinder. Refer to BRAKE MASTER CYLINDER, REMOVING AND INSTALLING, LHD VEHICLES .

Hybrid vehicles

-- Loosen the high-voltage cables from the brackets and move them to the side. Refer to the appropriate Service Information .

-- Remove the bracket for the high-voltage cables from the transmission. Refer to the appropriate Service Information .

Vehicles with 12 V luggage compartment battery

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-- Remove the bolt -5-.

-- Unclip the wiring harness -2 and 3-.

-- Release the power distribution panel -1- from the bracket -arrow-.

-- Release and remove the connector -4-.

-- Move the power distribution panel -1- to the side.

Vehicles with Diesel Engine:

-- Remove the air duct pipe. Refer to AIR DUCT PIPE, REMOVING AND INSTALLING, DNFC, DNFE, DNFF, DNFG, DSFB, DSFE AND DSFF .

Vehicles with DSG transmission:

-- Remove the selector lever cable and cable bracket from the transmission. Refer to OVERVIEW - SHIFT MECHANISM .

Continuation for All Vehicles:

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

-- Remove the nuts -3 and 4- from the brake booster.

Fig 3: Brake Booster

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-- Carefully remove the brake booster from the bulkhead.

-- Carefully remove the brake booster from the vehicle.

-- Remove the remaining bonded joint -arrows- from the brake booster -2- and the bulkhead -1-.

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-- Using a hot air gun, warm the adhesive residue at a low setting and remove it.

-- Clean the surfaces thoroughly.

Installing:

Install in the reverse order of removal while noting the following:

-- Replace the seal between the brake booster and the bulkhead OVERVIEW - BRAKE BOOSTER/BRAKE MASTER CYLINDER .

-- 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  OVERVIEW - BRAKE BOOSTER/BRAKE MASTER CYLINDER, LHD fits correctly when attaching the brake master cylinder to the brake booster.

-- Make sure the plugs  OVERVIEW - BRAKE BOOSTER/BRAKE MASTER CYLINDER, LHD are seated correctly in the brake master cylinder.

-- Coat the plugs with brake fluid before pressing the brake fluid reservoir into the brake master cylinder.

-- Attach the brake pedal to the brake booster. Refer to BRAKE PEDAL, ATTACHING TO BRAKE BOOSTER .

-- Code the Brake Booster Control Module -J539- using the Vehicle Diagnostic Tester.

-- Perform the electromechanical brake booster basic setting using the Vehicle Diagnostic Tester.

Tightening Specifications

• Refer to OVERVIEW - BRAKE BOOSTER/BRAKE MASTER CYLINDER, LHD 
• Refer to the appropriate Service Information .
• Refer to the appropriate Service Information .
• Refer to BATTERY, DISCONNECTING AND CONNECTING .
• Refer to OVERVIEW - INSTRUMENT PANEL COVER, DRIVER SIDE .
• Refer to OVERVIEW - STEERING COLUMN .
• Refer to OVERVIEW - AIR ROUTING AND AIR DISTRIBUTION IN VEHICLE INTERIOR .
• Refer to the appropriate Service Information .