Hydraulic Brake Booster: Service and Repair

70.65.20


Remove
1. Disconnect battery negative lead.
2. Depressurize braking system.
3. RHD Vehicles Only: Release coolant expansion tank from clips and bracket. Position tank aside for access to booster pipe connections.





4. LHD Diesel Vehicles Only: Remove 2 bolts securing fuel filter assembly to chassis turret. Move filter aside.
5. Position cloth under booster to collect fluid spillage.
6. Release clip from fluid reservoir hose at pump. Disconnect hose.
7. Allow fluid to drain into suitable container. Discard fluid. Plug hose and pump.





8. Disconnect hose from reservoir. Plug hose and reservoir.

Manual Vehicles only.
9. Reposition container beneath clutch master cylinder feed hose.
10. Disconnect clutch hose from reservoir. Allow fluid to drain. Plug hose and reservoir.


All Models
11. Disconnect 2 multiplugs from booster.
12. Disconnect fluid level switch multiplug.
13. Remove banjo bolt securing high pressure hose to pump. Discard sealing washers. Plug hose and pump.
14. Unscrew pipe unions from booster. Plug pipes and booster.
15. Remove closing panel.





16. Release booster push rod from brake pedal.





17. Remove 2 bolts securing booster assembly to pedal box. Remove booster.





18. Remove banjo bolt securing high pressure hose to booster. Discard sealing washers. Plug hose and booster.


Refit
19. Remove plugs from high pressure hose and booster.
20. Position high pressure hose to booster. Secure with banjo bolt and new sealing washers. Tighten to 24 Nm (18 ft. lbs.)
21. Position booster to pedal box. Ensure push rod engages with pedal. Secure booster with bolts. Tighten to 45 Nm (33 ft. lbs.)
22. Remove plugs from brake pipes and booster. Align pipes to booster. Secure union nuts. Tighten to 14 Nm (10 ft. lbs.)
23. Remove plugs from high pressure hose and pump
24. Position high pressure hose to pump. Secure with banjo bolt and new sealing washers. Tighten to 24 Nm (18 ft. lbs.)
25. Connect fluid level switch multiplug.
26. Connect 2 multiplugs to booster.
27. Manual Vehicles only. Remove plugs from clutch fluid hose and reservoir. Connect hose. Secure with clip.
28. Remove plugs from reservoir, brake fluid hose and pump.
29. Position hose to reservoir and pump. Secure with new clips.
30. Remove cloth from under booster.
31. LHD Diesel Vehicles Only: Align fuel filter to chassis turret. Secure with 2 bolts.
32. RHD Vehicles Only: Engage coolant expansion tank beneath bracket. Engage with clips.
33. Reconnect battery negative lead.
34. Bleed braking system.
35. Fit Fascia closing panel.