Question 1

What precautions should be taken when disconnecting the battery and replacing the power brake booster on Volkswagen Jetta?

Accepted Answer

This should be done with care because when the battery is disconnected, there are a number of systems that will have to be re-learned in order to be used correctly. Some models have an automatic transaxle, where a vacuum pump supplies vacuum to the power brake booster along with manifold vacuum, installed close to the ABS/ESP hydraulic unit that supplies a vacuum hose to the brake booster. A dealer service department or qualified repair shop should perform diagnosis in case the system appears defective since the power brake booster is not serviceable and should be replaced in case it is faulty. The power brake booster is taken off as one piece together with the master cylinder. To carry out an operating check, press and release the brake pedal several times with the engine off to confirm that there is no change in the peddle reserve distance after which, the engine can be started and a slight drop in the peddle indicates that the system operates properly. To check the airtightness, begin the engine and turn it off after one to two minutes, depressing the brake pedal slowly a few times; the reduction in the amount of the pedal depression means that the booster is airtight. Turn the engine off, multiple presses on the brake pedal, remove the engine cover, separate the negative battery terminal, and pull out the battery and tray. Also to be removed are the driver side knee bolster, brake light switch and the removal of the booster pushrod off the brake pedal with a special tool that has been made. The master cylinder and vacuum hose attached to the brake booster located within the engine compartment is to be removed, clips, and any sound insulation panels. In models with a manual transaxle, the shift cables and brackets must be removed, whereas when it is an automatic transaxle, the transmission cooler line must be clamped and disconnected. The bottom trim panel and booster mounting nuts are removed in the car, the brake booster removed off the firewall, then the cowl compartment is detached and separated with the master cylinder. Installation: Assemble the master cylinder with the power brake booster when installing, making sure that the pushrod fits in correctly; and remove them in the part of the sequence that they were installed in. All mounting fasteners must be tightened to the torque values mentioned and to bleed the master cylinder an assistant must pump the brake pedal and hold it to the floor, loosening line fittings until none more air and fluid passes through at all. Enough rags to receive any leakage of brake fluid, which may damage painted surfaces should be available and once the brake system has been bled, the brakes should be put into operation to ensure the vehicle is set back to normal service. Also, on those models that have a manual transaxle, the clutch system will need bleeding as well as the brake system.

Question 2

How to perform an operating check and remove or install a power brake booster on Volkswagen Passat?

Accepted Answer

In order to do an operating check, press the brake pedal multiple times with the engine off to verify that no difference in the distance of the pedal reserve. Then switch the pedal and turn on the engine, in case the pedal sinks a little, everything is fine but in case it does not, look at the vacuum hose and the vacuum at the intake manifold with a vacuum gauge. To check air tightness, turn the engine on and to turn the engine off after one or two minutes, then depress the brake pedal slowly many times: as the pedal gets less and less in depressing, the booster is airtight. Also when running the engine press the brake pedal and turn off the engine keeping the pedal depressed and in case there is no change in the pedal travel after keeping the pedal in the hold position of 30 seconds, then the engine booster is airtight. To remove the power brake booster pushrod, one will need a special tool to unattach it to the brake pedal, and therefore one must make sure that the tool is available prior to the setup. In case not available, it can be built using materials that are easily available. To start with the master cylinder, take it off, then take off the vacuum hose connection very carefully by pulling out of the grommet in the booster. To dismantle the vehicle, unscrew the two bolts of the booster and reach behind the brake pedal with the special tool to detach the pushrod ball of the pedal then return to the engine compartment and remove the gasket on the rear. To install, ensure that the grommet sealing the vacuum hose is not damaged and change accordingly. Measure the distance between the booster mounting surface and the end of the pushrod ball head, it should be 6.26 +/- 0.020 inches, adjust the length of pushrod. Install a new gasket on the back of the booster unit, reinstall it on the firewall and tighten the mounting bolts. Install the booster pushrod and the brake pedal and make sure the pedal is firmly hooked, fit the brake light switch and the master cylinder. Then, placing the vacuum hose back into the booster, carefully, without knocking out the sealing grommet. Lastly, empty the brake hydraulic system, activate the engine to probe to a vacuum leak at the vacuum hose-to-booster grommet and ensure the functionality of the brake system in a secluded location before going back to the regular service.

Genuine Volkswagen Brake Booster

64 Brake Boosters found

Volkswagen Brake Booster Part Number: 5QM-614-106-C

Volkswagen Brake Booster Part Number: 3QF-614-106-B

Volkswagen Brake Booster Part Number: 5Q1-614-106-R

Volkswagen Brake Booster Part Number: 5Q1-614-106-Q

Volkswagen Booster Assembly Part Number: 7P5-612-105-C

Volkswagen Brake Booster Part Number: 5N1-614-106-C-REP

Volkswagen Brake Booster Part Number: 5QM-614-106-D

Volkswagen Brake Booster Part Number: 8V1-612-107-A

Volkswagen Brake Booster Part Number: 1J1-614-106-H

Volkswagen Brake Booster Part Number: 8D0-612-107-B

Volkswagen Brake Booster Part Number: 3C1-614-106-P

Volkswagen Brake Booster Part Number: 3C1-614-106-Q

Volkswagen Brake Booster Part Number: 561-614-106-A

Volkswagen Booster Assembly Part Number: 1K1-614-106-AC

Volkswagen Brake Booster Part Number: 1H1-612-107-C

Volkswagen Brake Booster Part Number: 1J1-614-106-K

Volkswagen Brake Booster Part Number: 3C1-614-106-R

Volkswagen Brake Booster Part Number: 1K1-614-106-AB

Volkswagen Brake Booster Part Number: 561-614-106-E

Volkswagen Brake Booster Part Number: 1H1-612-107-D

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