Brake Booster

Brake Booster

• Check the brake boost vacuum first if there are complaints regarding the brake booster. Refer to => [ Brake Booster Vacuum System, Checking ] Testing and Inspection.

Special tools, testers and auxiliary items required

• Brake Charger/Bleeder Unit (VAS 5234)

• Torque Wrench (5-50 Nm) (V.A.G 1331)

Removing

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

- Depending on the engine version, remove only the intake tube or the intake tube and air filter housing.

- Disconnect the battery.

- Remove the battery.

- Remove the battery tray.

- 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 brake charger/bleeder unit (VAS 5234) or (V.A.G 1869/4).

with a 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 and then remove it.






Continuation for All

- Disconnect the connector - A - from the brake fluid level warning switch.

- Disconnect the connector - C - from the brake lamp switch.






- Remove the brake lines - 1 - from the master cylinder. Seal off the brake lines with plugs from the repair kit 1H0 698 311 A.

- Pull the vacuum hose out of brake booster.

- Remove the storage compartment from the trim mounts on the driver side.

- Remove the drivers side foot well vent.

- Remove the sound absorber on the brake pedal, if applicable.

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

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






- Carefully remove the brake booster from the vehicle.

- Remove both nuts - 2 - from the bracket if the brake booster gets caught in the holes.

- Remove the master cylinder from the brake booster.

- Remove the heat shield, if equipped.

- Carefully take the master cylinder out of the brake booster.

Installing

- Install in the reverse order of removal.

Observe the following points when installing:

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

- After installing, bleed the brake system, refer to => [ Brake System, Bleeding ] Service and Repair and the clutch.