Brake Booster, Removing And Installing: Removing

WARNING: This page is about a different car, the 2014 Volkswagen Touareg, 2013 Volkswagen Touareg, 2012 Volkswagen Touareg, and 2011 Volkswagen Touareg. However, it is still accessible from the selected car via links, so may be relevant.

Special Tools And Workshop Equipment Required

Brake Charger/Bleeder Unit:VAS5234

-- Remove the left plenum chamber cover. Refer to PLENUM CHAMBER BULKHEAD .

-- Remove the engine compartment seal near the brake booster.

-- Remove the left bulkhead from the plenum chamber. Refer to PLENUM CHAMBER BULKHEAD .

-- Pull the E-box in the plenum chamber out of the mounting and move it to the side. Refer to E-BOXES .

-- Remove the bolts -arrows- and remove the cover for the Connection and Junction Box 2 -SX2-.

Fig 1: Identifying E-Box Cover

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Depending on the vehicle equipment, disconnect all multi-pin connectors.

-- Pull the front wiring harness out of the bulkhead and move it together with the E-box as far as possible to the side.

-- Remove the retaining pin for the E-box in the plenum chamber.

-- Remove the connector -2- from the Brake Lamp Switch -F- -1-.

Fig 2: Brake Lamp Switch -F- -1-. And Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the connector from the Brake Fluid Level Warning Switch -F34-.

-- Place enough lint-free cloths in the plenum chamber in the area of the brake master cylinder.

-- Extract as much brake fluid as possible from the brake fluid reservoir using the Brake Charger/Bleeder Unit:VAS5234 or the Brake Charge and Bleed Equipment:VAG1869/4 .

-- Pull the brake line out of the bracket in the plenum chamber.

-- Remove the brake lines -A and B- from the brake master cylinder.

Fig 3: Brake Master Cylinder

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Seal the brake lines and brake master cylinder using the Plugs:1H0 698 311 A from the repair kit.

-- Pull vacuum hose out of brake booster.

-- Remove the footwell cover. Refer to FOOTWELL COVERS, REMOVING AND INSTALLING .

-- Disconnect brake pedal from brake booster. Refer to BRAKE PEDAL, REMOVING FROM BRAKE BOOSTER .

-- Remove the nuts -arrows- from the brake booster.

Fig 4: Identifying Brake Booster Nuts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Carefully remove the brake booster from the plenum chamber.

-- Remove the brake master cylinder from the brake booster.