Brake Booster
Brake Booster
Special tools, testers and auxiliary items required
• Brake Filler/Bleeder Unit (VAS 5234)
• Torque Wrench (V.A.G 1331)
Removing
- If the vehicle has a coded radio, get the radio code from the customer before beginning.
- Disconnect battery.
- Remove intake hose, air filter housing (on vehicles with diesel engine and some gasoline engines) and battery.
On vehicles with 6-cyl. gasoline engine, battery is in luggage compartment, accordingly only air filter housing with bracket must be removed.
- 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 the brake fluid reservoir. Use the (VAS 5234) or (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 Ha 4590 and then remove it.
All Vehicles
- Remove the connector - A - from the brake fluid level warning switch (F34).
- Pull off connector - C - from brake lamp switch (F).
- On vehicles with HBV, pull off connector from brake booster vacuum sensor (G483).
- Pull vacuum hose out of brake booster.
Vehicles with Manual Transmission
- Remove the cable - 1 -, and the mounting bracket - 2 - and lay it aside.
Vehicles with Automatic Transmission
- Open the cable channel, pull the wiring harness for Servotronic out, then remove the cable channel from the console and lay it aside.
- Pry off the selector lever cable, remove it from the mounting bracket and retainer and lay it aside.
- Remove the retainer from the selector lever cable.
Additionally, on vehicles with 2.0L 110 kW FSI engine:
- Remove the connecting tube for the EGR system and remove the bracket for the coolant hose on the cylinder head.
All Vehicles
- Disconnect the brake lines at the brake master cylinder and seal the lines with sealing plugs from repair kit part number. 1H0 698 311 A.
and also on vehicles with 6-cyl. gasoline engine:
- Remove the nuts for the brake master cylinder.
- Carefully remove master brake cylinder from brake booster as well as heat shield.
- Remove brake booster vacuum sensor (G483). Refer to => [ Brake Booster Vacuum Sensor ] Brake Booster Vacuum Sensor.
All Vehicles
- Remove footwell trim on driver side.
- Remove the nuts - arrows - and remove foot well trim - 1 -.
- Disconnect brake pedal from brake booster. Refer to => [ Brake Pedal and Brake Booster ] Brake Pedal and Brake Booster.
- Remove the nuts - 1 - from brake booster.
- Loosen both upper nuts - 2 - from the mounting bracket.
- Carefully remove brake booster from vehicle.
- Remove the nuts for the brake master cylinder.
- Carefully remove the brake master cylinder from the brake booster.
Installing
- Installation is 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 mount and push the brake pedal toward the brake booster until the ball
head engages audibly. ] Brake Pedal and Brake Booster.
- After installing, bleed brake system. Refer to => [ Brake System, Bleeding ] Brake System, Bleeding and clutch.
