5-Cylinder Gasoline 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)

• Hose clamp pliers (VAS 6340)

• Engine bung set (VAS 6122)

• Plug (1H0 698 311 A)

Removing

- Open the clamps to remove the 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.

- Loosen the spring clamp - 3 - to remove the intake hose - 4 - between the throttle valve control module (J338) and the air filter.






- Press the locking rings together to remove the air hose - 2 -.

Vehicles with Secondary Air Injection System






- Remove the hoses - arrows -.

- Remove the intake hose from the throttle valve control module.

- Disconnect the connectors - arrows -.






- Remove the air pipe - 1 - from the secondary air injection solenoid valve (N112).

- Open the bracket - 3 - and move the air pipe to the side.

Continuation for All Vehicles






- Remove the vacuum line - 1 - from the brake booster - 2 -.

- Remove the vacuum hose - 2 - (if equipped).






- Open the bracket - arrow - and free up the vacuum line - 1 -.

- Pull the vacuum line - 1 - of the vacuum pump and then remove the vacuum line - 1 -.

Vehicles with Automatic Transmission






- Open the retainer and remove the automatic transmission control module (J217).

- Unclip the wiring harness on the bracket and move the transmission control module to the side.

- Remove the screws - 1 - and - 6 -.

Vehicles with Hydraulic Power Steering

- Remove the bolts - 1 - and - 6 -.

- Move the bracket - 7 - with the power steering fluid reservoir to the side.

Continuation for All Vehicles

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

- Remove battery and the battery carrier.






- 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 (VAS 5234).

Vehicles with Automatic Transmission

- Remove the noise insulation or impact guard.

- Remove the selector lever cable.

- Move the selector lever into P.






- To remove the selector lever cable from the transmission, first disconnect the cable - 1 - and then remove it from the cable bracket - 2 -.

• Do not use pliers otherwise the tabs on the cable could break off.

• Do not bend the selector lever cable.

- Remove the cable - 1 - from the lever - 3 - using an open-end wrench - 2 -.






- Remove the selector lever cable bracket from the transmission.






- Seal the coolant hoses with (3094).






- Remove the coolant hose from the ATF cooler.

Continuation for All Vehicles






- Seal the coolant hoses with (3094).

- Remove the coolant hoses - arrows - from the heater core.

- Move the coolant hoses to the side.

- 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.

- Remove the bracket from the selector mechanism on 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

- 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.

- 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 -.

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

With Manual Transmission

- Bleed the clutch.

Vehicles with Automatic Transmission






- The selector lever cable bracket must not touch the ATF cooler.

Continuation for All Vehicles






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

- Check the coolant level.

- Install and connect the battery.

- 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