2.0L TFSI Engine
Brake Booster
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.
• 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 and the battery tray.
- Remove bolts - Arrows -.
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 brake filler/bleeder unit (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.
- Disconnect brake pedal from brake booster. Refer to => [ Brake Pedal and Brake Booster, Separating and Connecting ] Brake Pedal and Brake Booster, Separating and Connecting.
- Remove the threaded connection - 1 - from the brake booster on the pedal bracket.
• It is not necessary to loosen the threaded connection - 2 -.
Continuation for All Vehicles
- Carefully remove the brake booster from the vehicle.
Installing
Install in reverse order of removal. Note the following:
- Carefully install the brake booster and tighten the nuts hand-tight.
- 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.
- Clip the brake pedal to the brake booster. Refer to => [ Hold the push rod ball head in front of the mount and push the brake pedal toward the brake booster until the ball head engages audibly. ] Brake Pedal and Brake Booster, Separating and Connecting.
Follow the Tightening Sequence
- Tighten bolts - 1 - through - 4 - in the same sequence as illustrated.
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
