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Home >> Volvo >> 2011 >> S40 T-5 R-Design >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Hydraulic-Vacuum-Hydraulic Brakes - Cleaning, Inspection And Adjustment (544 Body) >> Vacuum Pump, Tank, Line And Valve (2004-2011) >> Brake Booster, Replacing >> Removal

Brake Booster, Replacing: Removal

REMOVING PROTECTIVE COVERS 

Fig 1: Identifying Clips And Protective Cover
G00491491Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove: 

Fig 2: Identifying Plastic Nut And Upper Protective Cover For Firewall
G00491492Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove: 

REMOVING THE PEDAL SENSOR 

Fig 3: Identifying Pressure Sensor and Connector
GLL139914Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove: 

Fig 4: Removing Pedal Sensor
GLL139915Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the pedal sensor. Widen the snap ring and pull out the pedal sensor.

HINT: The opening on the snap ring points straight down. The snap ring does not need to be completely removed, just opened. 

NOTE:

Ensure that the O-ring is also removed.

REMOVING THE HEAT DEFLECTOR PLATE 

Fig 5: Identifying Heat Deflector Plate And Brake Hoses
G00491502Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove: 

REMOVING THE BRAKE PIPE 

Fig 6: Identifying Brake Tubes And Nuts
G00491503Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove: 

REMOVING THE MASTER CYLINDER 

Remove the master cylinder. See: MASTER CYLINDER, BRAKE .

REMOVING SOUNDPROOFING PANELS 

Remove the soundproofing panel. See: INSTRUMENT PANEL LOWER .

REMOVING THE POWER BRAKE BOOSTER 

Fig 7: Removing Power Brake Booster Pin
GLL140029Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the pin for the power brake booster.

NOTE:

The pin cannot be removed entirely. It must be replaced with a new pin on installation.

Fig 8: 4 Nuts Holding Power Brake Booster
GLL140030Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove: