Brake Booster

Brake Booster

Special tools, testers and auxiliary items required

• Brake filler/bleeder unit (VAS 5234)

Removing

- Remove the left plenum chamber cover.

- Remove engine compartment seal near of brake booster.

- Remove the left plenum chamber bulkhead.

- Remove the E-Box inside the plenum chamber from its mount and move it to the side.

- Remove the bolts - arrows - and the cover from connection/conjunction box 2 (SX2).






- Disconnect all multipin connectors, depending on the equipment level.

- Remove the front wiring harness from the bulkhead and move it to the side together with the E-box.

- Remove the bolt for the E-box inside the plenum chamber.

- Disconnect the connector - 2 - from the brake lamp switch (F) - 1 -.






- Disconnect the connector from the brake fluid level warning switch (F34).

- Place sufficient lint-free cloths in plenum chamber in the area of the brake master cylinder.

- Extract as much brake fluid as possible from brake fluid reservoir using (VAS 5234) or extraction device upgrade kit (V.A.G 1869/4).

- Remove the brake line from the bracket in the plenum chamber.

- Remove the brake lines on the master brake cylinder - A and B -.






- Seal off the brake lines and master brake cylinder using the sealing plugs (1H0 698 311 A) from the repair kit.

- Pull vacuum hose out of brake booster.

- Remove the footwell cover.

- 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 nuts - arrows - from brake booster.






- Carefully remove brake booster from plenum chamber.

- Remove the brake master cylinder from the brake booster.

Installing

- Install in reverse order of removal.

Observe the following points when installing:

• Clip the brake pedal to the brake booster.

- 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.

- Bleed the brake system. Refer to => [ Brake System, Bleeding ] Brake System, Bleeding.