Brake Master Cylinder, Removing and Installing
Brake Master Cylinder, Removing and Installing
Special tools, testers and auxiliary items required
^ Hose clamps, up to diameter 25 mm VAS 3094
^ Brake Filler and Bleeder Unit VAS 5234
1. Valve dome transportation protection (plastic foam)
2. M10 sealing plugs for brake lines and threaded holes
3. M12 sealing plugs for brake lines and threaded holes
Removing
- Remove engine cover panel where necessary for access to components.
- Remove screws - arrows -.
- Remove forward left-hand cover panel.
- If installed, disconnect secondary air intake hose -1- from air cleaner.
- Disconnect air hose -2- from mass air flow sensor.
- Unplug connector -3- from mass air flow sensor.
- Unscrew bolts -4- and -5-.
- Remove air cleaner housing.
- Lay out sufficient lint-free cloths in area below brake master cylinder to catch escaping brake fluid.
- Draw off as much brake fluid as possible from brake fluid reservoir using Brake Filler and Bleeder Unit VAS 5234 or Extraction Unit VAG 1869/4.
- Clamp off clutch master cylinder supply hose with Hose clamps, up to diameter 25 mm VAS 3094.
- Pull off clutch master cylinder supply hose.
- Pull connector off float warning indicator sender if part of original equipment.
- Pull connectors - arrows - off brake pressure sensors - a - and - b -.
- Disconnect brake lines on brake master cylinder and seal brake lines with plugs from repair kit.
- Remove securing nuts from brake master cylinder.
- Remove heat shield with retainer plate, if part of original equipment.
- Remove brake master cylinder from brake booster.
Installing
Install in reverse sequence; note the following points:
- Replace sealing ring between brake master cylinder and brake booster.
- When inserting brake master cylinder, make sure that push rod in brake booster is correctly positioned.
- Apply slight pressure to the brake pedal; this makes it easier to guide brake master cylinder onto pushrod.
- Bleed brake system.
- Bleed hydraulic system for clutch
- Initiate basic settings for brake pressure senders.
- Perform ESP road test on vehicles with ABS/ESP Mark 60 system. ABS/ESP Components, ITT Mark 60
Tightening Specifications
