Brake Booster

Brake Booster

Special tools, testers and auxiliary items required

• Brake Filler/Bleeder Unit (VAS 5234)

• Release Tool (T10159)

• Torque Wrench (V.A.G 1331)

Removing

- On vehicles with a coded radio, note the code. Retrieve it if necessary.

- Disconnect battery.

- Remove the air filter.

- Remove the battery.

- Remove the battery carrier.

- Open the cable channel, remove both wiring harnesses and lay them aside.

- Remove the cable channel from the console.

- 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. Use the (VAS 5234).

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

- Remove the connector - A - from the brake fluid level warning switch (F34).

- Pull off connector - C - from brake lamp switch (F).

- Pull vacuum hose out of brake booster.

- Mark both brake lines from the brake master cylinder to the hydraulic unit and remove them.

- Plug the brake lines and threaded holes immediately with sealing plugs from the repair kit Part No. 1H0 698 311 A.

- Remove the nuts - arrows - and remove foot well trim - 1 -.





- Remove the noise insulation on the brake pedal, if applicable - 3 - => [ Noise Insulation on the Brake Pedal ] Brake Pedal Assembly Overview.

- 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.

- Remove the nuts for the brake master cylinder.

- Carefully remove the brake master cylinder from the brake booster.

Installing

- Installation is in reverse order of removal.

Observe the following points when installing:

- Make sure the boot is installed correctly.

- Clip the brake pedal to the brake booster => [ Hold the push rod ball head in front of
the mount and push the brake pedal toward the brake booster until 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.