6-Cylinder Gasoline Engine

Brake Booster

Special tools, testers and auxiliary items required

• Brake filler/bleeder unit (VAS 5234)

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.

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.

- Remove the bracket from the selector lever cable on the transmission.

Continuation for All Vehicles






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






- 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.

- 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.

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 -.

- Install and connect the battery.

Tightening Specification