2.0L TFSI Engine

Master Brake Cylinder

Special tools, testers and auxiliary items required

• Release tool (T10159 A)

• Sealing tool (T10249)

• Torque wrench (V.A.G 1331)

• Brake filler/bleeder unit (VAS 5234)

• Plug (1H0 698 311 A)

• Hose clamp pliers (VAS 6340)

• Engine bung set (VAS 6122)

Removing






- Remove the engine cover upward at the attaching points - arrows -.

- Remove the intake hose.

- Seal off all openings with (VAS 6122).

• Disconnect battery ground strap for all further work. See if a coded radio is installed. Get the anti-theft code beforehand, if necessary.

- Remove the battery.

Danger of causing damage to electronic components when disconnecting the battery.

• Complete the steps for disconnecting the battery.

- Place sufficient lint-free cloths in the area of the engine and transmission.

- Extract as much brake fluid as possible from the brake fluid reservoir using (VAS 5234).

Vehicles with DSG Transmission

- Remove the selector lever cable from the ball head and out of the cable bracket.

- Remove the selector lever from the selector shaft on the transmission.

Continuation for All Vehicles






- Remove the star-shaped washers - arrows -.

- Disconnect the connector.

- Unclip the connector and wiring harness from the bulkhead.

- Fold the bulkhead damper - 1 - forward in - direction of arrow - and remove it.

• It is not necessary to remove the insulation.

With Manual Transmission

- Remove the supply hose - 2 - for the clutch master cylinder - 3 - from the brake fluid reservoir - 4 -.






- Seal the supply hose - 2 - for the clutch master cylinder - 3 - using (T10249) - 1 - or (VAS 6122).

- Seal off the supply hose - 2 -.

- Remove the selector mechanism from the transmission.

• It is necessary to separate the cable retainer from the selector cable prior to removing to prevent damaging the selector cable.

Continuation for All Vehicles






- Remove the vacuum line - 1 - from the brake booster.

- Disconnect the connector - 1 - from the brake fluid level warning switch (F34).






- Remove the brake line tube fitting - 2 -.

- Seal off the brake line with the plug (1H0 698 311 A).

- Remove the fastener - 2 - in - direction of arrow -.






- Carefully remove the brake fluid reservoir - 1 - from the plug.

- Release and disconnect the connector - 1 - from the brake lamp switch (F) - 2 -.






- Unclip the cable bracket from the master brake cylinder.

- Remove the brake line tube fitting - 2 - from the master brake cylinder - 1 -.






- Seal off the brake line with the plug (1H0 698 311 A).

- Unscrew the threaded connection - arrows - on the brake master cylinder - 1 -.

- Carefully take brake master cylinder out of brake booster.

Installing

Install in reverse order of removal. Note the following:

- When installing together the brake master cylinder and brake booster, make sure that the push rod is correctly located in the brake master cylinder.

- Make sure the seal fits correctly when attaching the master brake cylinder to the brake booster.

Coat the plugs with brake fluid before pushing the brake fluid reservoir into the master brake cylinder.

- Bleed the brake system. Refer to => [ Brake System, Bleeding ] Service and Repair.

With Manual Transmission

- Bleed the clutch.

Continuation for All Vehicles






- Insert the tab on the vacuum line - 1 - into the opening - arrow - in the brake booster - 2 -.

- Battery, Installing and Connecting.

- Make sure the rubber buffers fit correctly in the mounts when installing the engine cover.






Before installing the engine cover, make sure the 4 mounting elements (ball sockets) are correctly positioned; adjust them if necessary. Otherwise the engine cover will get damaged.

Tightening Specification