2.5L Engine

Master Brake Cylinder

Special tools, testers and auxiliary items required

• Sealing tool (T10249)

• Torque wrench (V.A.G 1331)

• Brake filler/bleeder unit (VAS 5234)

• Hose clamp pliers (VAS 6340)

• Engine bung set (VAS 6122)

Removing

- Disconnect the connector - 1 - and intake hose - 2 -.






- Remove the bolts - 3 - and the intake hose.

- Remove the engine cover from the fasteners first at the front - arrow 1 -, then at the rear on the right side - arrow 2 - and finally at the rear on the left side - arrow 3 - with a quick pull.






- Carefully remove the engine cover at the rear.

• 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).






- 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.

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 -.

Continuation for All Vehicles






- 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.

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

- 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