Brake Booster

Brake Booster

Special tools, testers and auxiliary items required

• Engine Bung Set (VAS 6122)

• Release Tool (T10159 A)

• Sealing Tool (T10249)

• Torque Wrench (V.A.G 1331)

• Brake Filling And Bleeding Equipment (VAS 5234)

Removing

- Remove the battery and the battery tray. Refer to => Electrical Equipment 27 Battery, Disconnecting and Connecting.

- 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 (VAS 5234).

- Remove the star-shaped washers - arrows -.






- Fold the bulkhead damper - 1 - forward in - direction of arrow -.

Vehicles with DSG transmission

- Remove the selector lever cable from the ball head and from the cable mounting bracket.

- Remove the selector lever from the selector shaft on the transmission.

With Manual Transmission

- Remove the supply hose - 1 - to the clutch master cylinder - 2 - from the brake fluid reservoir.






- Seal off the connection for the supply hose to the clutch master cylinder - 2 - using the (VAS 6122).

- Seal off the supply hose - 1 - using the (T10249).






2 (T10249)

Continuation for all vehicles






- Remove the vacuum line - 1 - from the brake booster.

- Disconnect the connector - 1 - from the brake fluid level warning switch (F34).






- Remove the brake line tube fitting - 2 -.

- Seal off the brake line with the plug (1H0 698 311 A).

- Remove the fastener - 2 - in direction of arrow.






- Carefully remove the brake fluid reservoir - 1 - from the plug.

- Release and disconnect the connector - 1 - from the brake lamp switch (F) - 2 -.






- Unclip the cable bracket from the master brake cylinder.

- Remove the brake line tube fitting - 2 - from the master brake cylinder - 1 -.






- Seal off the brake line with the plug (1H0 698 311 A).

- Unscrew the threaded connection - arrows - on the brake master cylinder - 1 -.

- Carefully take brake master cylinder out of brake booster.

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

- Remove the threaded connection - 1 - from the brake booster on the pedal bracket.






• It is not necessary to loosen the threaded connection - 2 -.

Vehicles without a manual transmission






- Remove the star-shaped washers - arrows -.

- Fold the bulkhead damper - 1 - forward in - direction of arrow -.

Continuation for all vehicles

- Carefully remove the brake booster from the vehicle.

Installing

Install in reverse order of removal. Note the following:

- Carefully install the brake booster and tighten the nuts hand-tight.

- Clip the brake pedal to the brake booster; refer to => [ 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, Separating and Connecting.

Follow the tightening sequence






- Tighten bolts - 1 - through - 4 - in the same sequence as illustrated.

Coat the plugs with brake fluid before pushing the brake fluid reservoir into the master brake cylinder.

- Battery, installing and connecting, refer to.

- Bleed the brake system. Refer to => [ Brake System, Bleeding ] Service and Repair.

With Manual Transmission

- Bleed the clutch.

Tightening Specification