Brake Booster

Special tools and workshop equipment required

Hose clamps 3093
Hose clamps 3094
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

Removing

-- Note or request radio code on vehicles with coded radio if necessary.

-- Disconnect battery. Refer to [For transmission(s) 0A4, 02E, 09G, 02Q] [For engine(s) BRM, BGP, BPY, BGQ, CBTA, CBEA, CJAA, CBUA, CCTA, CBFA] Removal and Installation .

Diesel vehicles

-- Disconnect connection -1- and remove rear spring hose clamp from intake hose.

Fig 1: Locating Electrical Connection And Spring Clamp

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-- Remove spring hose clamp -arrow- and remove hose from air filter housing.

Fig 2: Identifying Spring Hose Clamp

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-- Remove bolt from air filter housing -arrow-.

Fig 3: Identifying Air Filter Housing Bolt

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-- Move air filter housing upward out of brackets and remove.

Continuation for all vehicles

-- Remove battery. Refer to [For transmission(s) 0A4, 02E, 09G, 02Q] [For engine(s) BRM, BGP, BPY, BGQ, CBTA, CBEA, CJAA, CBUA, CCTA, CBFA] Removal and Installation .

-- Remove the battery carrier.

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

-- Extract as much brake fluid as possible from brake fluid reservoir using VAS 5234 or V.A.G 1869/4.

With Manual Transmission

-- Disconnect clutch master cylinder supply hose -B- with 3094.

-- Pull off supply hose -B- for clutch master cylinder.

Fig 4: Identifying Clutch Master Cylinder And Supply Hose

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Continuation for all vehicles

-- Disconnect connector -A- from floating warning indicator sensor.

Vehicles with the Brake Light Switch -F- on the Master Brake Cylinder

-- Disconnect the connector -1- from brake light switch.

Fig 5: Identifying Removal Of Brake Light Switch F From KW 45/05

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Continuation for all Vehicles

-- Remove brake fluid reservoir, press the engagement straps toward outside at reservoir and simultaneously pull brake fluid reservoir out of sealing plugs.

Fig 6: Identifying Brake Master Cylinder, Brake Lines And Nuts

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-- Remove the brake lines -1- on master brake cylinder, seal brake lines using Sealing plugs 1H0 698 311 A.

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

-- If present, remove heat shield.

-- Carefully take brake master cylinder out of brake booster.

-- Disconnect vacuum hose from brake booster.

With Manual Transmission

-- Loosen cables -1-, unscrew bracket -2- and set it aside. Refer to SHIFT CABLE AND SELECTOR CABLE .

Fig 7: Identifying Cable And Mounting Bracket

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Vehicles with Automatic Transmission

-- Clamp off coolant line at cooler for automatic transmission using 3093 and two 3094 and disconnect from cooler for automatic transmission.

Fig 8: Identifying Clamped Off Automatic Transmission Coolant Lines

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Continuation for all Vehicles

-- Remove footwell trim on driver side. Refer to Removal and Installation .

Vehicles with the Brake Light Switch -F- on the Brake Pedal

-- Disconnect connector -1- from brake light switch.

Fig 9: Identifying Brake Light Switch And Connector

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-- Remove brake light switch -2- by rotating 45° toward left.

Continuation for All Vehicles

-- Disconnect brake pedal from brake booster. Refer to SEPARATING AND CONNECTING BRAKE PEDAL AND BOOSTER .

-- Remove the nuts -1- from brake booster.

Fig 10: Identifying Brake Booster Fasteners

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-- Carefully remove brake booster from vehicle.

Installing

-- Installation is performed in the reverse sequence.

Observe the following points when installing:

-- Clip brake pedal together with brake booster. Refer to SEPARATING AND CONNECTING BRAKE PEDAL AND BOOSTER .

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

-- Bleed brake system after installing. Refer to BRAKE SYSTEM, BLEEDING WITH BRAKE FILLER/BLEEDER UNIT VAS 5234 OR VAG 1869 .

-- Bleed clutch. Refer to [For transmission(s) 02E] [For engine(s) BRM, BPY, CBEA, CJAA, CCTA, CBFA] General Information .

-- Adjust brake light switch. Refer to BRAKE LIGHT SWITCH, THROUGH 10.05.2005 .

Tightening Specifications

Component	Tightening Specifications
Brake booster to foot pedal assembly/cross panel Use new nuts!	25 Nm
Master brake cylinder at brake booster Use new nuts!	25 Nm
Brake lines to master brake cylinder	14 Nm
Battery holder to body	20 Nm