Brake Booster, Removing And Installing: Removing

WARNING: This page is about a different variant/trim than selected.

-- Disconnect the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

-- Remove the air filter housing. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Free up the wires -2- with the :80-200 on the bracket -1- for the air filter housing.

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-- Remove the bolts -arrows- and the bracket.

Vehicles with 2.0L TFSI Engine:

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-- Remove the noise insulation. Refer to NOISE INSULATION, REMOVING AND INSTALLING, COUPE .

-- Free up the wiring harness -1 and 2- from the air duct pipe.

-- Loosen the screw-type clamp -4-.

-- Remove the bolts -arrows- and press the air duct pipe forward.

NOTE:

Ignore item -3-.

Vehicles with a TDI Engine

Fig 1: Identifying Vacuum Hose

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-- Disconnect the vacuum hose -arrow- and free it up.

-- Press the release button on the crankcase ventilation hose -1- and remove the hose from the cylinder head cover.

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-- Free up the vacuum hose on the air duct pipe -arrows-.

-- Remove the bolt -2- and pivot the air duct pipe with the intake tube toward the rear and remove it from the turbocharger.

NOTE:

Ignore item -3-.

-- Remove the bolts -arrows-.

Fig 2: Identifying Bolts, Clamp & Air Guide Pipe

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-- Loosen the clamp -2-, and remove the air duct pipe -1-.

-- Remove the bolts -arrows- and the resonator -1-.

Fig 3: Identifying Reasonator With Bolts

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Continuation for All Vehicles

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-- Remove the ground bolt -1-.

-- Disconnect the connector -2-.

-- Open the E-box in direction of -arrow-, remove the B+ wire -4- and remove the nuts -3-.

-- Remove the E-box -5- upward.

WARNING:

Brake fluid is caustic risk of skin injury.

To prevent skin contact with brake fluid, wear chemical resistant safety gloves.
Do not extract brake fluid by mouth.
Brake fluid is poisonous and must never be swallowed.

WARNING:

Brake fluid is caustic risk of skin injury.

Do not extract brake fluid by mouth.

Brake fluid is poisonous and must never be swallowed.

To prevent skin contact with brake fluid, wear chemical resistant safety gloves.

Brake fluid contact with fluids containing mineral oils causes malfunctions.

Brake fluid must never come into contact with fluids containing mineral oils (oil, gas, cleaning solutions). Safety gloves must be free of oil and grease.

Risk of damaging the painted surfaces.

Due to its corrosive nature, brake fluid must also never contact paint. Wash off any spilled brake fluid immediately with plenty of water.

-- Place sufficient lint-free cloths in the area of the engine and transmission.

Fig 4: Identifying Brake Charger/Bleeder Unit VAS5234

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-- Siphon as much brake fluid as possible using the :VAS5234 with the :VAS5234/1 from the brake fluid reservoir.

Vehicles with Manual Transmission

Fig 5: Identifying Supply Hose & Seals

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-- Remove the return hose -1- to the clutch master cylinder, seal it with the :T10249 and tie it up.

Continuation for All Vehicles

Fig 6: Component Location - Brake Lamp Switch -F- /Brake Pedal Switch -F63- and Vacuum Sensor -G608-.

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-- Disconnect the connectors:

from the Brake Lamp Switch -F-
from the Vacuum Sensor -G608-, if equipped
from the Brake Fluid Level Warning Switch -F34-

-- Remove the vacuum in the brake booster by pressing the brake pedal repeatedly.

Fig 7: Identifying Vacuum Hose

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CAUTION:

There is a risk of damaging the vacuum hose by removing.

Replace the vacuum hose if damaged.

-- Carefully pull the vacuum hose -arrow- out of the brake booster.

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

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-- Remove the brake lines -1- on brake master cylinder.

-- Immediately seal the open connection points with clean plugs from the Assembly Part Set:5Q0 698 311 .

-- Remove the nuts -2- for the brake master cylinder.

-- Remove the heat shield if present.

-- Carefully remove the brake master cylinder from the brake booster.

NOTE:

For better clarity, the brake master cylinder is shown without the brake fluid reservoir.

Vehicles with DSG^® Transmission

-- Remove the selector lever cable and cable bracket from the transmission. Refer to OVERVIEW - SHIFT MECHANISM .

Continuation for All Vehicles

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

-- Remove the nuts -arrows- and move the footwell trim panel to the side.

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-- Remove the nuts -3 and 4- for the brake booster.

Fig 8: Brake Booster - Tightening Sequence

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NOTE:

Ignore items -1 and 2-.

-- Pull the brake booster off the bonding on the bulkhead and remove it.