Brake Booster, Removing And Installing, Vacuum Brake Booster: Removing

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

All Vehicles Excluding Vehicles with 2.5L TFSI Engine:

-- Remove the battery tray. Refer to BATTERY TRAY, REMOVING AND INSTALLING .

Vehicles with 2.0L TFSI Engine:

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-- Remove the noise insulation. Refer to OVERVIEW - NOISE INSULATION .

-- 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.

Vehicles with a TDI Engine:

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-- Free up the vacuum hoses -arrows-.

-- Loosen the hose clamps -1 and 2- and remove the air duct pipe.

-- Remove the bolts -arrows-.

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-- Loosen the screw-type clamp -3- and remove the air duct pipe -1-.

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

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Vehicles with 2.5L TFSI engine:

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

-- Remove the air filter housing. Refer to the appropriate Service Information .

-- Free up the wiring harness on the bracket -1- for the air filter housing.

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

-- Remove the jump start terminal from the bracket and move to the side. Refer to BATTERY JUMP START TERMINAL, REMOVING AND INSTALLING .

Continuation for All Vehicles:

Fig 1: Identifying Brake Charger/Bleeder Unit VAS5234

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

CAUTION:

Leaking brake fluid increases the risk of injury.

Risk of skin irritation and injury.

- Wear safety gloves.

-- Open the brake fluid reservoir.

CAUTION:

Risk of accident due to the brakes malfunctioning.

- Brake fluid must never come into contact with fluids containing mineral oils (oil, gasoline, cleaning solutions).

- Wear safety gloves that are free of oil and grease.

-- Extract as much brake fluid as possible from the brake fluid reservoir using the Brake Charger/Bleeder Unit: VAS5234 with the Adapter: VAS5234/1 .

Vehicles with Manual Transmission:

Fig 2: 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 3: 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-

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

-- Remove the vacuum hose from the brake booster at the same time do not damage it.

-- Remove the union bolts -1- for the brake lines.

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-- Immediately close open connection points with a clean plug.

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

-- Remove any heat shield.

-- Carefully remove the brake master cylinder from the brake booster. (Brake master cylinder shown without brake fluid reservoir.)

Vehicles with Dual-Clutch Transmission:

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

Continuation for All Vehicles:

-- Remove the crash bolster. Refer to OVERVIEW - INSTRUMENT PANEL CROSSMEMBER .

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

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

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