Brake Booster

Brake Booster

Removing

Special tools, testers and auxiliary items required

• Torque Wrench 5-50 Nm (V.A.G 1331)

• Adapter (VAS 5234/1)

• Brake Charger/Bleeder Unit (VAS 5234)

• Sealing Plugs Repair Kit, Part no. (1H0 698 311 A)

- Switch the engine off.

- Press the brake pedal until there is no more brake assistance - "pump the brake booster empty". The brake pedal becomes hard.

- Remove the driver side storage compartment - 1 to 3 -.






- Disconnect the connector - C - on the footwell vent.






- Remove the footwell vents - A-B -.

- Remove the brake lamp sensor, refer to => [ Brake Lamp Sensor ] Service and Repair.

- Separate the brake pedal from the brake booster, refer to => [ Brake Pedal and Brake Booster, Disconnecting and Connecting ] Brake Pedal and Brake Booster, Disconnecting and Connecting.

- Remove the engine cover.

- Remove the plenum chamber cover.

- Remove the tower brace.

- Remove the plenum chamber.

- Remove the brake fluid reservoir, refer to => [ Brake Fluid Reservoir ] Brake Fluid Reservoir.

- Remove the brake master cylinder at the nuts - 3 -, refer to => [ Master Brake Cylinder ] Master Brake Cylinder.






- Remove the brake master cylinder from the vehicle.

- Place the brake master cylinder so no brake fluid can drain out.

- Remove the vacuum line - 3 - from the brake booster.






- Remove the bolts mounting the brake booster - 1 - to the mounting bracket.






- Remove the brake booster from the vehicle.

Installing

- Insert the brake booster in the vehicle.

Make sure the seal is seated correctly.

- Install the bolts from the brake booster - 1 - to the mounting bracket and tighten them.






- Press the vacuum line - 3 - into the brake booster.






- Install the brake master cylinder, refer to => [ Master Brake Cylinder ] Master Brake Cylinder.

- Install the brake fluid reservoir, refer to => [ Brake Fluid Reservoir ] Brake Fluid Reservoir.

- With manual transmissions, insert the clutch hydraulic line - 5 - into the brake fluid reservoir.






- Fill the brake fluid up to the marking.

- Bleed the brake system, refer to => [ Brake System, Bleeding ] Service and Repair.

- With manual transmissions, bleed the clutch.

- Install the plenum chamber bulkhead

- Install the tower brace

- Install the engine cover.

- Install plenum chamber cover

Brake Pedal and Brake Booster, Connecting

- Hold the push rod ball head in front of the mount and push the brake pedal toward the brake booster, so that the ball head clicks into place.

- Install the brake lamp sensor, refer to => [ Brake Lamp Sensor ] Service and Repair.

- Install the footwell vent - A -.






- Connect the connector - C - on the footwell vent.

- Install the driver side storage compartment - 1 to 3 -.