Brake Booster

Brake Booster

Special tools, testers and auxiliary items required

• Brake Filler/Bleeder Unit (VAS 5234)

• Torque Wrench 5-50 Nm (V.A.G 1331)

Removing

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

- Disconnect battery.

On Vehicles with Diesel Engine:

- Disconnect connection - 1 - and remove rear spring hose clamp from intake hose.






- Remove spring hose clamp - arrow - and remove hose from air filter housing.






- Remove screw from air filter housing - arrow -.






- Move air filter housing upward out of brackets and remove.

All Vehicles

- Remove and install 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 brake fluid reservoir using (VAS 5234).

For Vehicles 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.






All Vehicles

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

- Disconnect the connector from the brake lamp switch (F) (only on vehicles from calendar week 45/05).

- 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.

- Remove the nuts - 2 - from master brake cylinder.

- If present, remove heat shield.

- Carefully take brake master cylinder out of brake booster.

- Pull vacuum hose out of brake booster.

For Vehicles with Manual Transmission:

- Remove the cables - 1 -, remove the bracket - 2 - and move it to the side.






All Vehicles

- Remove trim on driver side.

Brake lamp switch is no longer present on mounting bracket from CW 45/05.

- Disconnect connector - 1 - from brake lamp switch.






- Remove brake lamp switch - 2 - by rotating 45° toward left.

- Remove air channel - 3 -.

- Remove cover - 4 -.

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

- Remove the nuts - 1 - from brake booster.






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

- Carefully remove brake booster from vehicle.

Installing

- Installation is performed in the reverse sequence.

Observe the following points when installing:

- Clip brake pedal together with brake booster => [ 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

- After installing, bleed brake system. Refer to => [ Brake System, Bleeding ] Brake System, Bleeding and clutch.