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

- 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) or extraction device (V.A.G 1869/4).

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 (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 light 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, Separating from Brake Booster ] Brake Pedal, Separating from 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

- Install in reverse order of removal.

Observe the following points when installing:

- Clip brake pedal together with brake booster, refer to => [ ] Brake Pedal, Separating from Brake Booster.

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

Only on vehicles up to calendar week 45/05:

- Brake light switch, installing, refer to => [ Brake Lamp Switch (F), through 04 November 2005 ] Brake Lamp Switch (F), through 04 November 2005.