Brake Master Cylinder, TT RS

Removing

Special tools and workshop equipment required

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

-- Remove the engine cover -1-.

Fig 1: Removing Engine Cover -1- Upward -Arrows-

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-- Remove bolts -arrows- and remove the air guide.

Fig 2: Identifying Air Guide And Bolts

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-- Remove the bolts -arrows- and remove the air filter housing.

Fig 3: Identifying Air Filter Housing Component Location

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-- On the TT RS remove the brake lamp switch. Refer to BRAKE LAMP SWITCH, TT RS .

-- To protect against escaping brake fluid, place enough lint-free cloths in the area below the master brake cylinder.

-- Extract as much brake fluid as possible from brake fluid reservoir using brake charger/bleeder unit VAS 5234 or extraction device upgrade kit V.A.G 1869/4.

WARNING:

Brake fluid must never come into contact with fluids containing mineral oils (oil, gas, cleaning solutions). Mineral oil damages the sealing plugs and boots of the brake system.
Brake fluid is poisonous. NEVER siphon brake fluid with your mouth! Also due to its corrosive effect, brake fluid must not come into contact with paintwork.
Observe disposal regulations.

-- Connect connector on brake fluid level warning switch.

-- Disconnect brake lines -3- at brake master cylinder and seal brake lines with sealing plugs from repair kit.

Fig 4: Brake Lines At Brake Master Cylinder And Seal Brake Lines With Sealing Plugs

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-- Remove brake master cylinder nuts -1-.

-- Remove heat shield.

-- Unclip brake fluid reservoir at Pos. -2- and pull upward and off.

-- Remove brake master cylinder from brake booster.

Installing

Installation is the reverse of removal, with special attention to the following:

-- Replace sealing ring between brake master cylinder and brake booster.

-- When replacing brake master cylinder, ensure pressure rod in brake booster is seated correctly.

-- Use new nuts -1-. Note torque. See item 6

Fig 5: Brake Lines At Brake Master Cylinder And Seal Brake Lines With Sealing Plugs

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-- Press brake pedal down a bit, this allows the brake master cylinder to be guided into pressure rod more easily.

-- Install brake lines -3- on brake master cylinder. Note torque. See item 7

-- On the TT RS install the brake lamp switch. Refer to BRAKE LAMP SWITCH, TT RS .

-- Install the brake fluid reservoir BRAKE FLUID RESERVOIR .

-- Install the air filter housing and tighten the bolts -arrows-.

Fig 6: Identifying Air Filter Housing Component Location

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-- Install the air guide and tighten the bolts -arrows-.

Fig 7: Identifying Air Guide And Bolts

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-- Install the engine cover.

-- Brake System: ABS/ESP Mark 60, bleeding BRAKE SYSTEM BLEEDING .

-- Initiate brake pressure sensor basic setting.

Use Vehicle Diagnosis, Testing and Information System VAS 505x for this.

-- Perform ESP driving and system test.

Vehicle diagnostic, test and information System VAS 505x

-- Under chassis

-- Brake system (Repair Group 01; 45)

-- 01 - On Board Diagnostic (OBD) capable systems

-- 03- Brake electronics ABS/ESP Mark 60 si

-- J104- ABS/ASR/ESP Control Module, Functions

WARNING:

Make sure the brakes are working correctly before driving the vehicle for the first time.