Brake Booster

Brake Booster

Special tools, testers and auxiliary items required

• Hose clamps (3093)

• Hose clamps (3094)

• 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)

Removing

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

- Disconnect battery.

Diesel vehicles

- 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 bolt from air filter housing - arrow -.





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

Continuation for all vehicles

- Remove 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) or (V.A.G 1869/4).

With Manual Transmission

- Disconnect clutch master cylinder supply hose - B - with (3094).

- Pull off supply hose - B - for clutch master cylinder.





Continuation for all vehicles

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

Vehicles with the Brake Light Switch (F) on the Master Brake Cylinder

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





Continuation for all Vehicles

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





- Remove the brake lines - 1 - on master brake cylinder, seal brake lines using Sealing plugs (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.

- Disconnect vacuum hose from brake booster.

With Manual Transmission

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





Vehicles with Automatic Transmission

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





Continuation for all Vehicles

- Remove footwell trim on driver side.

Vehicles with the Brake Light Switch (F) on the Brake Pedal

- Disconnect connector - 1 - from brake light switch.





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

Continuation for All Vehicles

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

- Remove the nuts - 1 - from brake booster.





- 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. Refer to => [ Separating and Connecting Brake Pedal and Booster ] Separating and Connecting Brake Pedal and Booster.

- Connect the battery.

- Bleed brake system after installing. Refer to => [ Brake System, Bleeding with Brake Filler/Bleeder Unit VAS 5234 or VAG 1869 ] Brake System, Bleeding with Brake Filler/Bleeder Unit VAS 5234 or VAG 1869.

- Bleed clutch.

- Adjust brake light switch. Refer to => [ Brake Light Switch, through 10.05.2005 ] .

Tightening Specifications