6-Cylinder Gasoline 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:

- Remove the air filter.

- Remove the throttle valve control module (J338) intake hose.

- Remove the bolts - arrows - from the air filter housing bracket.






- Remove the bracket.

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

- Disconnect 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).

- Open the clips in - direction of arrow A - and open the cover - 1 -.






- Open the cover - 2 - in - direction of arrow B -.

- Remove the nuts - 5 - and - 6 -.






- Disconnect the connector - 1 - from the suppressor (C24) - 4 -.

- Remove the bolt - 3 - and the positive terminal grip - 2 -.

- Remove the bolts - arrows - and then remove the bracket - 1 - from the positive terminal grip on the bulkhead.






- Disconnect the connectors.






- Remove the cable bracket from the bulkhead.

- 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).

- Pry the brake fluid reservoir - 1 - off the retainers - arrows - on the master brake cylinder - 2 -.






- 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 hydraulic system. Refer to => [ Hydraulic System, Bleeding ] Service and Repair.

Tightening Specification