Brake Booster

Brake Booster

• If the vehicle has a TFSI engine, then the noise amplifier must be removed and installed. Refer to => [ Noise Amplifier, TFSI ] Service and Repair.

• The noise amplifier is inside the engine compartment in front of the brake booster.






1 - Brake Booster

2 - Brake Light Switch

• To brake booster.

6 - Nut

• Always replace after removal.

• 25 Nm

8 - Brake Pedal

Special tools, testers and auxiliary items required

• Torque wrench (V.A.G 1331)

• Brake filler/bleeder unit (V.A.G 1869)

• Brake filler/bleeder unit suction adapter (V.A.G 1869/4)

• Brake filler/bleeder unit (VAS 5234)

• Sealing plugs repair kit, Part no. (1H0 698 311 A)

• Vehicle Diagnosis, Testing and Information System (VAS 505x)

Removing

- Remove the vacuum in the brake booster by pressing the brake pedal repeatedly.

- Depending on the engine installed, remove the noise amplifier. Refer to => [ Noise Amplifier, TFSI ] Service and Repair.

- Remove brake light switch. Refer to => [ Brake Light Switch ] Brake Light Switch.

- Remove brake master cylinder. Refer to => [ Brake Master Cylinder ] Brake Master Cylinder.

• Remove brake booster vacuum sensor (G483) depending on model. Refer to => [ Brake Booster Vacuum Sensor, with Optimized Hydraulic Brake Vacuum (OHBV) Boosting ] Service and Repair.

- Unclip and remove the vacuum line from the brake booster.

- Remove driver side compartment.

- Disconnect brake pedal from brake booster. Refer to => [ Brake Pedal and Brake Booster, Separating ] Brake Pedal and Brake Booster, Separating.

- Remove the nuts - 6 -.






- Remove the brake booster from the vehicle.

Installing

Installation is the reverse of removal, with special attention to the following:

• Use new nuts.

- Observe torque: 25 Nm

- Clip brake pedal together with brake booster. Refer to => [ Brake Pedal and Brake Booster, Separating ] Brake Pedal and Brake Booster, Separating.

• Install brake booster vacuum sensor depending on model. Refer to => [ Brake Booster Vacuum Sensor, with Optimized Hydraulic Brake Vacuum (OHBV) Boosting ] Service and Repair.

- Install brake master cylinder. Refer to => [ Brake Master Cylinder ] Brake Master Cylinder.

- Install brake light switch. Refer to => [ Brake Light Switch ] Brake Light Switch.

- Depending on the engine installed, install the noise amplifier. Refer to => [ Noise Amplifier, TFSI ] Service and Repair.

- Install driver side compartment.

- Brake system bleeding, refer to => [ Brake System Bleeding ] Brake System Bleeding.

- Initiate brake pressure sensor basic setting.

• Use (VAS 505x) for this.

- Perform ESP driving and system test.

(VAS 505x).

- Under chassis

- Brake system (Repair Group 01; 45)

- 01- On Board Diagnostic (OBD) capable systems

- 03- Brake electronics ABS/ESP Mark 60si

- J104- ABS/ASR/ESP Control Module, Functions

- On vehicles with ABS/ESP, initiate brake pressure sensor basic setting.

- Perform ESP driving and system test.

Make sure the brakes are working correctly before driving the vehicle for the first time.