Brake Booster
Brake Booster
Special tools, testers and auxiliary items required
• Hose Clamps Up to 25 mm Dia. (3094)
• Torque Wrench (V.A.G 1331)
• Brake Filler/Bleeder Unit (V.A.G 1869)
• Brake Filler/Bleeder Unit Suction Adapter (V.A.G 1869/4)
• Brake Filler/Bleeder Unit (VAS 5234)
• Sealing Plugs Repair Kit, Part No. (1H0 698 311 A)
Removing
- Remove the engine cover.
- Disconnect the connector - 1 - on the mass airflow sensor.
- Disconnect the ventilation hose - 3 -.
- Remove the cover from the air filter housing.
- Disconnect the air guide at the clamp - 2 -.
- Move the air guide to the side.
- Remove the battery.
- Lay aside the air filter housing
- Remove the battery carrier - arrows -.
- Unhook the front of the battery carrier at the air duct.
- To protect against escaping brake fluid, place a lint-free rag in the area under the brake master cylinder.
- Draw off as much brake fluid as possible from brake fluid reservoir using (VAS 5234) or (V.A.G 1869/4).
- Clamp shut supply hose of clutch master cylinder using (3094).
- Pull off return hose for clutch master cylinder.
- Disconnect the connector at brake fluid level warning switch.
- Disconnect brake lines - 3 - at brake master cylinder and seal brake lines with sealing plugs from repair kit.
- Remove nuts - 1 - for brake master cylinder.
- Where necessary, remove the heat shield with retaining bracket.
- Pull off brake master cylinder from brake booster.
- Unclip brake fluid reservoir at - 2 - and pull upward and off.
Installing
Installation is in reverse order of removal, with special attention to the following:
- Replace the seal between the brake master cylinder and brake booster.
- Make sure that when inserting the brake master cylinder it is correctly positioned on the push rod in the brake booster.
- Press the brake pedal down slightly, making it is easier to guide the brake master cylinder into the push rod.
- Install the air guide.
- Secure the air guide with the clamp - 2 -.
- Install the cover on the air filter housing.
- Install the ventilation hose - 3 -.
- Connect the connector - 1 - to the mass airflow sensor.
- Install the engine cover.
- Bleed the brake system: ABS/ESP Mark 60. Refer to => [ Bleeding Brake System, ITT ABS/ESP Mark 60/ABS Mark 70 ] Bleeding Brake System, ITT ABS/ESP Mark 60/ABS Mark 70.
- Bleed the clutch hydraulic system.
- Perform a basic setting to brake pressure sensor 1 (G201) on vehicles with ABS/ESP.
Use the vehicle diagnosis, testing and information system (VAS 5051 B) or (VAS 5052).
- Perform the ESP driving and system tests.
Use the vehicle diagnosis, testing and information system (VAS 5051 B) or (VAS 5052).
- Under chassis
- Brake system (Repair Group 01; 45)
- 01- On Board Diagnostic (OBD) capable systems
- 03- Brake electronics ABS/ESP Mark 60
- J104- ABS/ASR/ESP Control Module, Functions
Tightening Specifications
Replace nuts