Power Brake Assist: Service and Repair

Brake Servo, Removing And Installing

Special tools, test equipment and auxiliary items
^ Sealing plugs repair kit, Part No. 1HO 698 311A
^ 3289 Brake pedal release tool

CAUTION: Part numbers are listed here for reference only.

Removing
- Remove driver's side storage compartment.
- Attach bleeder hose and bleeder bottle to left-front brake caliper bleeder screw and open bleeder screw.
- Operate brake pedal to pump out as much brake fluid as possible.
- Close left-front bleeder screw.
- Cover engine compartment to catch any spilled brake fluid.

CAUTION: Brake fluid must not be allowed to come into contact with paint work because of its caustic effect.





- On vehicles with manual transmissions, disconnect clutch master cylinder supply hose -1- and seal with plug.
- Disconnect harness connector from brake fluid level warning switch -2-.





- Disconnect brake lines -1- on brake master cylinder and seal brake lines and threaded holes using plugs from repair kit.
- Remove T45 Torx(R) bolts -2- from brake servo.
- Disconnect vacuum hose from brake servo.
- Remove brake light switch. On vehicles with cruise control system, also remove vent valve.





- Attach 3289 brake pedal release tool to brake pedal, as shown.
- Disconnect brake pedal from push rod.
- Remove brake servo together with brake master cylinder from plenum chamber.

Installing
Note the following points:
- Adjust brake light switch.
- Adjust vent valve for cruise control system (if equipped).

Bleeding clutch hydraulics
- Connect VW1238/B or VAG1869 but do not switch on yet.
- Open bleeder screw on clutch slave cylinder.
- Attach collector bottle hose.
- Switch on bleeder unit and allow approx. 100 cc (6 oz.) of brake fluid to flow out of clutch slave cylinder.
- Close bleeder screw.
- Bleed brake system.