Fitting

Caution!
Material damage to the connection to the brake pedal if the tightening torque used on the connecting pin is too great!

^ It is essential to observe the specified tightening torque on the connection thread bushing/pin.





1. Install new brake pushrod -9.1-. Tighten the threaded bushing -arrow- of the pin to 10 Nm (7.5 ft-lb.) (Please observe)!





2. Insert seal -7.2- (without lubricant) into the firewall. It is essential to ensure correct seating! Then insert (push in) the connection sleeve -7.1- into the seal -7.2- using rubber sliding compound for example Capella or tyre mounting paste. Recheck that it is seated correctly and correct if necessary!

3. Mount seal -7.3- and coat with Capella or tyre mounting paste.





4. Mount intermediate piece -11- (2 M8 nuts and hexagon socket head bolt). Tightening torque of the 2 M8 nuts = 23 N.m (17 ft-lb.)

5. Install battery.





6. Install new pushrod (if not already present) -12.1 - in place of -12-. When doing so, observe installation dimension X (138 mm).





Basic setting of the push rod -dimension X- is 138 mm (set in new brake boosters)! If necessary, correct during the relevant work!





7. Install brake booster and brake master cylinder with mounted bellows -B- and tightened clamps -6-.

Note!
Before using the brake booster, push the screw clamp -6.1- onto the bellows -B- or onto the brake pushrod!





8. Tighten fastening screws of brake booster (Torx T 45) -arrow- to 23 Nm (17 ft-lb.). Fit the vacuum line for the brake booster.

- If the brake master cylinder has been removed, tighten the fastening nuts (M14) to 49 Nm (36 ft-lb.).





9. Connect the 2 push rods. To do so, mount the fastening nuts -arrow-.
Note!
^ Adjusting the brake pushrod length changes the position of the brake pedal.

^ Perform a fine adjustment of the brake pushrod if the correct position of the brake pedal is not given!

^ After the brake pushrod is adjusted, check the brake light switch adjustment!





10. Check the position of the brake pedal -Dimension X 45 + 5 mm- Perform measurement between the centre of the brake pedal plate and the accelerator. Perform a fine adjustment of the brake pushrod if the correct position of the brake pedal is not given.





- Precise adjustment of brake pushrods: Undo the lock nut for this purpose and the turn the push rod accordingly at the hexagon -arrow- until -dimension X 45 + 5 mm- has been achieved. Subsequently re-tighten the the lock nut.





11. Check the setting of the brake light switch -(1)- The pedal must move a perceptible distance of approx. 5 to 10 mm before the brake light lights up. At the same time, check (make sure) that the brake light lights up before the pedal meets perceptible resistance or before brake pressure builds up. If necessary, set/re-adjust --> Rep. Gr. 46; Check brakelight setting.





12. Fit the bellows -B- to the connection sleeve -7.1- and secure with the screw clamp -arrow-.

13. If necessary, fit the alarm horn to the intermediate piece and clip in the air-conditioning line.

14. Install hydraulic unit and boost pump (in vehicles with PSM).

15. Bleed the brakes Serv. No. 47 01 07 (vehicle with and without TC) and Serv. No. 41 01 07 - vehicle with PSM.





Note!
^ First bleed brakes as usual!

^ Only after the conventional bleeding should the return pump actuation be performed (continue bleeding) with the Porsche System Tester 2 in vehicles with TC (Traction Control) or the booster pump control in the case of vehicles with PSM! If this is not observed, damage can occur to the return pump/booster pump!

^ To bleed at rear on right with running return pump (TC) or at front right with running booster pump (PSM), the bleeding device remains connected and switched on! Bleeding pressure approximately 2.0 bar!

16. Bleed the clutch in manual transmission vehicles 30; Rep. Gr. 30 01 07; Bleed the clutch system.

17. When replacing the hydraulic unit in vehicles with ABS/TC or PSM (4-channel system), code the control module (manual transmission or Tiptronic).

18. Carry out the following tests:

- Check the system (brake lines and connections) for leaks.

- Read out and erase the fault memory of the ABS or PSM control module with the Porsche System Tester 2 (PST 2). Additionally, perform the static test in the system.

- Check electrical and hydraulic lines (brake lines) for incorrect assignment using the PST 2.

Note!
The exchange test checks that the brake lines/solenoid valves are assigned to the correct brake calipers (wheels).

- Then start the engine. The ABS and if necessary also the PSM related lights in the instrument cluster must go out when the engine is running.

- Carry out a function check of the brakes. Then perform a short test drive and perform at least one ABS control operation, taking the road conditions into consideration. Read out the ABS or PSM fault memory again. There must not be any stored faults.

19. Perform the work which is necessary due to disconnecting the battery --> Rep. Gr. 9 Work instruction after disconnecting the battery.

20. Fit all covers and spare wheel (if available).