Brake Booster, With 5-Cylinder Gasoline Engine: Removing

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

-- Open clamp -2- and disconnect intake hose.

Fig 1: Disconnecting Connector And Intake Hose

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-- If equipped, disconnect the connector -1- and remove.

-- Remove the bolts -3- and the intake hose.

-- Pull the engine with a jerk out of the mounts first at the front -arrow 1-, then at the right rear -arrow 2- and finally at the left rear -arrow 3-.

Fig 2: Removing Engine Cover

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-- Carefully swivel engine cover out of rear area.

-- Release and remove hoses -arrows- on the intake hose.

Fig 3: Identifying Intake Hose And Throttle Valve Unit

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NOTE: Some vehicles are equipped with a 1 or 2 connectors on the intake hose.

-- Remove the intake hose from the Throttle Valve Control Module -J338-.

-- If equipped, disconnect and remove the connector -arrows-.

Fig 4: Identifying Vent Pipe

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-- If equipped, release and remove the vent pipe -1- on the Secondary Air Injection Solenoid Valve -N112-.

-- If equipped, open the bracket -3- and set the vent pipe aside.

-- Remove the vacuum line -1- from the brake booster -2-.

Fig 5: Identifying Vacuum Hose

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-- Remove the vacuum hose -2- (if equipped).

Fig 6: Disconnecting Vacuum Hose

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-- Open the bracket -arrow- and free up the vacuum line -1-.

-- Pull the vacuum line -1- off the vacuum pump and then remove the vacuum line -1-.

Vehicles with Automatic Transmission

Fig 7: Identifying Bolts, Connector, Transmission Control Module And Bracket

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-- Release the retaining tab and remove the Transmission Control Module -J217- from the bracket.

-- Unclip the wiring harness on the bracket and move the Transmission Control Module -J217- to the side.

-- Remove the bolts -1- and -6-.

Vehicles with Power Steering

-- Remove the bolts -1- and -6-.

-- Move the bracket -7- with the power steering fluid reservoir to the side.

Continuation For All Vehicles

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

Fig 8: Identifying Battery Housing Bolts

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-- Remove the bolts -arrows-.

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 9: 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.

Vehicles with Automatic Transmission

-- Remove the noise insulation or impact guard. Refer to Removal and Installation .

-- Remove the selector lever cable from the transmission. Refer to [For transmission(s) 09G] Removal and Installation .

-- Move the selector lever into >>P<<.

Fig 10: Identifying Cable Disengaged And Removed From Mounting Bracket

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-- To remove the selector lever cable from the transmission, first disconnect the cable -1- and then remove it from the cable bracket -2-.

NOTE:

Do not use pliers otherwise the tabs on the cable could break off.

Do not bend or kink the selector lever cable.

-- Pry the cable -1- off the lever -3- using a -2-.

Fig 11: Identifying Selector Lever Cable, Lever/Selector Shaft And 10 mm Open-End Wrench

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-- Remove the selector lever cable bracket from the transmission.

Fig 12: Identifying Selector Lever Cable Retainer And Bolts

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-- Position the Hose Clamps - Up To 25 mm 3094 on the coolant hoses and close them.

Fig 13: Hose Clamps Position On ATF Cooler Hoses

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-- Remove the coolant hose from the ATF cooler.

Continuation for all vehicles

Fig 14: Identifying Spring Clamps And Radiator Coolant Hoses

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-- Position the Hose Clamps - Up To 25 mm 3094 on the coolant hoses -arrows- and close them.

-- Remove the coolant hoses -arrows- from the heater core.

-- Move the coolant hoses to the side.

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

Fig 15: Removing Brake Master Cylinder

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-- 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.

Vehicles with a Manual Transmission

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

Fig 16: Identifying Supply Hose

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-- 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 [For transmission(s) 0A4] Removal and Installation or [For transmission(s) 02Q] [For engine(s) CVCA, CPLA, CJAA, CPPA, CCTA, CBFA] Removal and Installation or [For transmission(s) 02E] [For engine(s) CPLA, CJAA, CPPA, CCTA, CBFA] Removal and Installation .

-- Remove the bracket from the selector mechanism on the transmission. Refer to [For transmission(s) 0A4] Removal and Installation or [For transmission(s) 02Q] [For engine(s) CVCA, CPLA, CJAA, CPPA, CCTA, CBFA] Removal and Installation or [For transmission(s) 02E] [For engine(s) CPLA, CJAA, CPPA, CCTA, CBFA] Removal and Installation .

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

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.

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

Fig 17: Identifying Connector & Warning Switch

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-- 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 18: 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 19: 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 20: 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 21: Locating Pedal Bracket Nuts

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

-- Carefully remove the brake booster from the vehicle.