Brake Booster, Removing And Installing, RHD Vehicle

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

  Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Hybrid vehicles

-- Observe the safety precautions when working on the high-voltage system. Refer to SAFETY PRECAUTIONS WHEN WORKING ON THE HIGH-VOLTAGE SYSTEM .

-- Pay attention to the high-voltage system danger classification. Refer to the appropriate Service Information .

Vehicles with emissions control module:

-- Remove the emissions control module. Refer to ENGINE CONTROL MODULE J623, REMOVING AND INSTALLING .

Vehicles with a particulate filter:

-- Remove the particulate filter. Refer to PARTICULATE FILTER DIFFERENTIAL PRESSURE SENSOR G1037, REMOVING AND INSTALLING .

Vehicles with Parking Heater:

-- Remove the coolant pipes from the bulkhead. Refer to the appropriate Service Information .

Vehicles with catalytic converter:

-- Remove the catalytic converter. Refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING, FWD , CATALYTIC CONVERTER, REMOVING AND INSTALLING, AWD .

Continuation for All Vehicles:

-- Disconnect the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

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

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

-- Remove the nuts -arrows- from the mounting bracket.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Pull the brake booster off of the bonded seal of the bulkhead.

-- Move the brake booster to the side.

-- Remove the brake booster downward.

-- Carefully remove the brake booster from the vehicle.

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

-- 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, RHD.

-- 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, RHD fits correctly when assembling the brake master cylinder with the brake booster.

-- Make sure the sealing plugs  OVERVIEW - BRAKE BOOSTER/BRAKE MASTER CYLINDER, RHD 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.

Continuation for All Vehicles:

-- 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, RHD 
• Refer to OVERVIEW - INSTRUMENT PANEL COVER, DRIVER SIDE .
• Refer to OVERVIEW - AIR ROUTING AND AIR DISTRIBUTION IN VEHICLE INTERIOR .