Brake Booster, Removing And Installing: Removing

-- Switch off the ignition.

-- Reduce the vacuum in the brake booster by pressing the brake pedal repeatedly.

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

-- To protect against escaping brake fluid, place enough lint-free cloths in the area below the brake booster.

Fig 1: Identifying Brake Charger/Bleeder Unit VAS5234

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-- Extract as much brake fluid as possible from the brake fluid reservoir using the :VAS5234 with the :VAS5234/1 .

-- Remove the plenum chamber cover. Refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .

-- Remove the brake fluid reservoir. Refer to BRAKE FLUID RESERVOIR, REMOVING AND INSTALLING .

-- Remove the plenum chamber bulkhead. Refer to OVERVIEW - BULKHEAD .

-- Disconnect the connector -1- on the Vacuum Sensor -G608- and on the Brake Lamp Switch -F- -4-.

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-- Remove the Vacuum Sensor -G608- -2-. Refer to Vacuum Sensor -G608-, REMOVING AND INSTALLING

CAUTION:

There is a risk of damaging the vacuum hoses.

Vehicles with Manual Transmission

-- Remove the return hose -1- to the clutch master cylinder, seal it with the :T10249 and tie it up.

Fig 2: Identifying Supply Hose & Seals

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Continuation for All Vehicles

-- Disconnect and remove the vacuum hose -1- from the brake booster.

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-- Remove the union bolts -3- for the brake lines, then remove the brake lines from the brake master cylinder and move them slightly to the side.

NOTE:

Do not change the shape of the brake lines.

-- Immediately seal the open connection points with clean plugs from the Assembly Part Set :5Q0 698 311 .

-- Remove the bolts -arrows-.

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-- Carefully pull the brake booster with the brake master cylinder out of the plenum chamber.