LEMON Manuals: Even more car manuals for everyone
Home >> Volvo >> 2021 >> S60 T5 R-Design, AWD >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Brakes - Hydraulic/Vacuum-Hydraulic - Removal, Replacement And Installation >> (Brake Booster) >> Brake Booster [2019, B4204T28] >> Removal And Installation

Removal And Installation

REMOVAL 

NOTE:

Removal steps in this procedure may contain installation details.

Perform High voltage battery disconnection. Refer to: [HIGH VOLTAGE BATTERY, DISCONNECTING AND CONNECTING]

Remove bushing push rod. Refer to: [BUSHING PUSH ROD]  

Remove the wiper mechanism, windscreen. Refer to: [WIPER MECHANISM, WINDSHIELD]

GLL1002479Courtesy of VOLVO CARS CORPORATION

Remove the screws.

Remove the marked part.

Torque:  M8, 24Nm

GLL1004507Courtesy of VOLVO CARS CORPORATION

Loosen the hose clamp.

Remove the hose.

GLL1005254Courtesy of VOLVO CARS CORPORATION

Remove the screws.

Disconnect the connectors.

Torque:  M6, 10Nm

GLL1018157Courtesy of VOLVO CARS CORPORATION

Remove the screws.

  1. Torque:  M6, 10Nm
  2. Torque:  M5, 5Nm
GLL1038240Courtesy of VOLVO CARS CORPORATION

Remove the screw.

Torque:  M6, 10Nm

GLL1031106Courtesy of VOLVO CARS CORPORATION

Remove the screw.

Fold marked part aside.

GLL1025752Courtesy of VOLVO CARS CORPORATION

Remove the screws.

Torque:  IGM, to Body frame, 13Nm

GLL1051310Courtesy of VOLVO CARS CORPORATION

Lift the marked component forward.

GLL1007932Courtesy of VOLVO CARS CORPORATION

Undo the hose from the connection.

GLL1037815Courtesy of VOLVO CARS CORPORATION

Disconnect the connectors.

Loosen the clip.

GLL1033534Courtesy of VOLVO CARS CORPORATION
WARNING:

Make sure that new nuts are installed.

Remove the nuts.

Torque:  Master cylinder, to Brake booster, 27Nm

GLL1014198Courtesy of VOLVO CARS CORPORATION
CAUTION:

Make sure that the components are not forcibly bent.

Fold marked part aside.

GLL1023628Courtesy of VOLVO CARS CORPORATION

Remove the screws.

Remove the marked part.

HINT: It may be necessary to twist or turn the component. 

Torque:  M8, 24Nm

TRANSFERRING COMPONENTS 

GLL1010045Courtesy of VOLVO CARS CORPORATION

INSTALLATION 

To install, reverse the removal procedure.

GLL1017633Courtesy of VOLVO CARS CORPORATION
NOTE:

Use new seals.

NOTE:

Make sure that the seal is correctly located.

Use:  Thread locker normal, 1161053

Connect High Voltage Battery. Refer to: [HIGH VOLTAGE BATTERY, DISCONNECTING AND CONNECTING]

Calibration according to: Diagnostics / Components / Control modules/ Central Electronic Module (CEM) / Diagnostic sequences / Calibration of brake pedal sensor and brake pedal angle sensor