Brake Booster

Brake Booster

Special tools, testers and auxiliary items required

• Hose clamps up to 25 mm dia. (3094)

• Torque wrench 5-50 Nm (VAG 1331)

• Brake filler/bleeder unit (VAG 1869)

• Brake filler/bleeder unit suction adapter (VAG 1869/4)

• Brake charger/bleeder unit (VAS 5234)

• Hose clamps up to 40 mm (3093)

Removing

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

- Disconnect the battery..

Diesel Vehicles

- Disconnect the electrical connector - 1 - and remove the rear spring hose clamp from the intake hose.





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





- Remove the bolt for the air filter housing - arrow -.





- Remove the air filter housing upward out of the brackets and remove.

Continuation for All

- 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 (VAS 5234) or the (VAG 1869/4).

With Manual Transmission

- Clamp the clutch master cylinder supply hose - B - using (3094).

- Remove the supply hose - B - for the clutch master cylinder.





Continuation for All

- Disconnect the electrical connector - A - for the floating warning indicator sensor.

Vehicles with Brake Light Switch on the Master Cylinder

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





Continuation for All

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





- Remove the brake lines - 1 - from the master cylinder, seal the brake lines using sealing plugs from the sealing plug repair kit (1H0 698 311 A).

- Remove nuts - 2 - for the master cylinder.

- If present, remove the heat shield.

- Carefully remove the master cylinder from the brake booster.

- Disconnect the vacuum hose from the brake booster.

With Manual Transmission

- Loosen the cables - 1 -, remove bracket - 2 - and set it aside.





With Automatic Transmission

- Clamp off the coolant line at the transmission cooler using the (3093) and two (3094) and disconnect from the cooler.





Continuation for All

- Remove the driver's side footwell trim..

Vehicles with Brake Light Switch on the Brake Pedal

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





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

Continuation for All

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

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





- 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 the ball head of the push rod in front of the mounting and push the brake pedal in the direction of the brake booster, so the ball head locates audibly. ] Brake Pedal from Brake Booster, Separating and Connecting

- Connect the battery..

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

- Bleed the clutch system.

- Adjust the brake light switch.

Tightening Specifications