Master Brake Cylinder, With 4-Cylinder Diesel 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.

Fig 1: Removing Engine Cover

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-- Remove engine cover near -arrows-.

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

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

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 -2-. Refer to [For transmission(s) 02E, 02Q] [For engine(s) CVCA, CJAA] Removal and Installation or [For engine(s) CVCA] Removal and Installation .

Fig 2: Air Filter, Assembly Over View

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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, 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 3: 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.

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

Fig 4: 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.

Vehicles with a Manual Transmission

Fig 5: 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-.

Continuation For All Vehicles

Fig 6: 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.

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

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

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

-- Pry the brake fluid reservoir -1- off the retainers -arrows- on the master brake cylinder -2-.

Fig 7: 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 8: 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 9: Identifying Master Brake Cylinder

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-- Seal the brake lines with the 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.