Brake Booster

Brake Booster

Special tools, testers and auxiliary items required

• Brake charger/bleeder unit (VAS 5234)

• Torque wrench 5 - 50 Nm (VAG 1331)

Removing

- Note or request radio code on vehicles with a coded radio, if necessary.

- Disconnect the battery.

- Remove the battery.

- Remove the battery carrier.

- 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 the brake charger/bleeder unit (VAS 5234) or extraction device (VAG 1869/4).

With Manual Transmission

- Disconnect the clutch slave cylinder return hose - B - and secure it out of the way or clamp it off with a commercially available tool such as the Hazet 4590 and then remove it.





Continuation for All

- Disconnect the connector - A - from the floating warning indicator sensor.

- Disconnect the connector from the brake light switch (only on vehicles from 11.05).

- Remove brake fluid reservoir, press the engagement straps toward outside at reservoir and simultaneously pull brake fluid reservoir out of sealing plugs.





- Disconnect the brake lines - 1 - at the brake master cylinder and seal the lines with sealing plugs from repair kit Part No. 1H0 698 311 A.

- Unscrew nuts - 2 - from main brake cylinder.

- If present, remove heat shield.

- Carefully take brake master cylinder out of brake booster.

- Disconnect vacuum hose from brake booster.

For vehicles with manual transmission:

- Remove the cable - 1 -, remove the mounting bracket - 2 - and lay it aside.





All Vehicles

- Remove trim on driver's side..

Brake light switch is no longer present on mounting bracket from 11.06.05.

- Disconnect the connector - 1 - from the brake light switch.





- Remove the brake light switch- 2 - by rotating it 45 degrees toward the left.

- Remove air channel - 3 -.

- Remove cover - 4 -.

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

- Remove the nuts - 1 - from the brake booster.





- Loosen the both upper nuts - 2 - from the mounting bracket.

- Carefully remove the brake booster from the vehicle.

Installing

- Installation is performed in the reverse sequence.

Observe the following points when installing:

- Clip the brake pedal together with brake booster. Refer to => [ Hold ball head of push rod in front of
mounting and push brake pedal in direction of brake booster, so the ball head
engages audibly. ] Brake Pedal and Brake Booster Separating.

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

- Bleed the clutch.

Only on vehicles up to 11.06.05:

- Install the brake light switch. Refer to => [ Brake Light Switch, through 11.05.05 ] Service and Repair.