Brake Booster: Removing

Special tools and workshop equipment required 

• Torque Wrench 5-50 Nm V.A.G 1331
• Adapter VAS 5234/1
• Brake Charger/Bleeder Unit VAS 5234
• Sealing Plugs Repair Kit, Part no. 1H0 698 311 A

-- Switch the engine off.

-- Press the brake pedal until there is no more brake assistance - "pump the brake booster empty". The brake pedal becomes hard.

-- Remove the driver side storage compartment -1 to 3-.

Fig 1: Identifying Driver Side Storage Compartment

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-- Disconnect the connector -C- on the footwell vent.

Fig 2: Identifying Footwell Vents

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-- Remove the footwell vents -A-B-.

-- Remove the brake lamp sensor, refer to BRAKE LAMP SENSOR .

-- Separate the brake pedal from the brake booster, refer to BRAKE PEDAL AND BRAKE BOOSTER, DISCONNECTING AND CONNECTING .

-- Remove the engine cover.

-- Remove the plenum chamber cover, refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .

-- Remove the tower brace, refer to TOWER BRACE, REMOVING AND INSTALLING .

-- Remove the plenum chamber, refer to OVERVIEW - BULKHEAD .

-- Remove the brake fluid reservoir, refer to BRAKE FLUID RESERVOIR .

-- Remove the brake master cylinder at the nuts -3-, refer to MASTER BRAKE CYLINDER .

Fig 3: Brake Booster Bolts, Brake Lines & Brake Master Cylinder Bolts

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-- Remove the brake master cylinder from the vehicle.

-- Place the brake master cylinder so no brake fluid can drain out.

-- Remove the vacuum line -3- from the brake booster.

Fig 4: Identifying Brake Master Cylinder Bolts

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-- Remove the bolts mounting the brake booster -1- to the mounting bracket.

Fig 5: Brake Booster Bolts, Brake Lines & Brake Master Cylinder Bolts

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-- Remove the brake booster from the vehicle.