Brake Booster, With 4-Cylinder Diesel Engine: Removing

WARNING: This page is about a different car, the 2016 Volkswagen Beetle, 2015 Volkswagen Beetle, 2014 Volkswagen Beetle, 2013 Volkswagen Beetle, and 2012 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Engine Cover

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-- Remove engine cover near -arrows-.

-- Observe the given sequence -1- through -4-.

-- Reach as far as possible under the engine cover.

CAUTION: The bracket for attaching the engine cover to the cylinder head could break if removed incorrectly. Always remove the engine cover according to the following procedure.

-- Remove the intake hose. Refer to INTAKE MANIFOLD .

-- Remove the cover for the air guide; disengage the side clips to do so -arrows-.

Fig 2: Air Duct Cover Slide Clips

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-- Release the left and right spring clips -arrow A- and disconnect the lower air guide -2-.

Fig 3: Disengaging Lower Air Guide

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-- Disengage the lower air guide from the mounts -3-.

-- To do this, swing the lower air guide slightly backward.

-- Disengage the air guide pipe -1- from the lower air guide -arrow B-.

-- Disconnect the connector -1- from the Mass Airflow Sensor -G70- and disconnect the hose -2-.

Fig 4: Identifying Mass Airflow Sensor -G70- Connector, Vacuum Line, Bolt And Clamp

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-- Loosen the clamp -4- and remove the air duct tube.

-- Remove the hose -3- and remove the air filter housing.

-- Close all openings using the Engine Bung Set VAS6122.

NOTE: To perform work sequence, the ground cable must be disconnected from battery. Check if a coded radio is installed. If so, obtain anti-theft coding beforehand.

-- Remove the battery. Refer to [For transmission(s) 0A4, 02E, 09G, 02Q] [For engine(s) CVCA, CPRA, CBTA, CPKA, CPLA, CJAA, CBUA, CPPA, CCTA, CBFA] Removal and Installation .

Fig 5: Identifying Battery Housing Bolts

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-- Remove bolts -arrows- to remove battery tray. Refer to [For transmission(s) 0A4, 02E, 09G, 02Q] [For engine(s) CVCA, CPRA, CBTA, CPKA, CPLA, CJAA, CBUA, CPPA, CCTA, CBFA] Removal and Installation .

CAUTION: Danger of causing damage to electronic components when disconnecting the battery.

Observe the steps for disconnecting the battery.

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

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

Fig 6: Identifying Hose From Brake Charger/Bleeding Unit VAS 5234

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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.
Extract brake fluid cannot be used again.
Observe the disposal regulations.

-- Press the release buttons and remove the crankshaft housing ventilation hose -1- from the cylinder head cover.

Fig 7: Identifying Release Buttons

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-- Disconnect the connector from the crankcase housing ventilation hose -1-.

-- Free up the vacuum hoses -arrows-.

-- Remove the bolt -2-.

-- Turn the air guide pipe to the rear and remove it.

-- If equipped, remove bolt -arrow-.

Fig 8: Identifying Turbocharger Warm Air Connection

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-- Remove the intake tube -1- for the preheater on the bracket.

-- Remove the bolt -arrow-.

Fig 9: Identifying Intake Tube

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-- Free up the electrical wires and the hoses on the left air guide pipe -1- using the Pry Lever 80 - 200.

-- Loosen the hose clamp -2- and remove the air guide pipe -1-.

Vehicles with Emissions Control Module

Fig 10: Identifying Bolts, Clamp And Air Guide Pipe

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-- Remove the bolts -arrows-.

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

Vehicles with a Direct Shift Gearbox (DSG)

-- Remove the selector lever cable from the ball head and out of the cable bracket. Refer to Selector Mechanism .

-- Remove the selector lever from the selector shaft on the transmission. Refer to Selector Mechanism .

Vehicles with a Manual Transmission

Fig 11: Identifying Supply Hose

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-- Remove the supply hose -2- for the clutch master cylinder -3- from the brake fluid reservoir -4-.

-- Seal the supply hose -2- for the clutch master cylinder -3- using Sealing Tool T10249 -1- or Engine Bung Set VAS6122.

-- Seal off the supply hose -2-.

-- Remove the selector mechanism from the transmission. Refer to Shift Mechanism .

NOTE: It is necessary to separate the cable retainer from the selector cable prior to removing to prevent damaging the selector cable.

Continuation For All Vehicles

Fig 12: Removing Brake Master Cylinder

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-- Remove the star-shaped washers -arrows-.

-- Release and disconnect the connector.

-- Unclip the connector and wiring harness from the bulkhead.

-- Fold the bulkhead damper -1- forward in direction of -arrow- and remove it.

NOTE: It is not necessary to remove the insulation.

-- Pull the vacuum line -1- out of the brake booster -2-.

Fig 13: Identifying Vacuum Hose

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-- Disconnect the connector -1- from the Brake Fluid Level Warning Switch -F34-.

Fig 14: Identifying Connector & Warning Switch

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CAUTION:

Brake lines must not be bent.

Do not confuse brake lines when connecting them.

Mark the lines in their installed position before removing them.

-- Remove the brake line tube fitting -2-.

-- Close the brake line with Plugs 1H0 698 311 A.

-- Remove the fastener -2- in direction of -arrow-.

Fig 15: Identifying Brake Fluid Reservoir

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-- Carefully remove the brake fluid reservoir -1- from the plugs.

-- Unlock and disconnect the connector -1- from the Brake Lamp Switch -F- -2-.

Fig 16: Identifying Brake Line Tube Fitting

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-- Unclip the cable bracket from the master brake cylinder.

-- Remove the brake line tube fitting -2- from the master brake cylinder -1-.

Fig 17: Identifying Master Brake Cylinder

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-- Close the brake line with Plugs 1H0 698 311 A.

-- Unscrew the threaded connection -arrows- on the brake master cylinder -1-.

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

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

-- Remove the threaded connection -1- from the brake booster on the pedal bracket.

Fig 18: Locating Pedal Bracket Nuts

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NOTE: It is not necessary to loosen the threaded connection -2-.

Continuation For All Vehicles

-- Carefully remove the brake booster from the vehicle.