Brake Master Cylinder With Brake Servo, Removing and Installing

Brake master cylinder with brake servo, removing and installing





Special tools and equipment

^ Release tool T40024

Removing
- Remove glove compartment driver's side.





Rotate the brake light switch -1- counter clockwise through 45° and pull it out.





- Separate the brake pedal from the brake servo using release tool T40024.

- Drawing off brake fluid with brake filler and bleeder unit VAS 5234
- Take off the cover of the plenum chamber.





- Lay out plenty of lint-free cloths in the area of the plenum chamber.
- Open the brake fluid reservoir.





- Open the brake fluid reservoir.





- Unplug the connector of the sender for the float warning indicator -1-.
- Disconnect vacuum hose -2-.





- Unscrew the bolt -1- attaching the brake fluid reservoir.

Notes:
^ Protect the plenum chamber against any escaping brake fluid.
^ The underside of the brake fluid reservoir clips into the brake master cylinder.

- To remove reservoir] press down locking lug and at the same time pull brake fluid reservoir out of sealing plugs.
- Pull off the brake fluid reservoir and lay it to one side.





- Unscrew brake lines -3- and seal with dummy plugs from repair kit Part No. 1H0698311 A
- Lay out plenty of lint-free cloths in the area of the hydraulic control unit.





- Unscrew brake lines -1- and -2- and take them out with the rubber grommet.





- Unscrew the bolts attaching the brake servo unit -1- (Torx T45).
- Remove brake servo with brake master cylinder.





- Unscrew the nuts attaching the brake master cylinder -1-.
- Carefully remove brake master cylinder from brake servo unit.

Installing
Pay special attention to the following on installation:
^ Before installing brake master cylinder, clean any residual brake fluid off plenum chamber.
^ When assembling brake master cylinder with brake servo unit, make sure push rod is properly positioned in brake master cylinder.

- Adjust brake light switch.
- Bleed brake system.