Master Brake Cylinder, With 4-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.

Vehicles with 2.0 L Gasoline Engine and Turbocharger:

Fig 1: Identifying Engine Cover Attachment Points

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-- Remove the engine cover upward from the attaching points -arrows-. Refer to [For transmission(s) 02E, 02Q] [For engine(s) CVCA, CJAA] Removal and Installation or [For engine(s) CPRA, CPKA, CPLA, CPPA] Removal and Installation or [For engine(s) CVCA] Removal and Installation or [For engine(s) CCTA, CBFA] Removal and Installation or [For engine(s) CBUA] Removal and Installation .

-- Remove the intake hose -2-. Refer to [For engine(s) CCTA, CBFA] Removal and Installation or [For engine(s) CBUA] Removal and Installation or [For engine(s) CPRA, CPKA, CPLA, CPPA] Removal and Installation .

Fig 2: Air Filter, Assembly Over View

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-- To do this, loosen clamps -1-.

-- Seal the openings with the Engine Bung Set VAS6122.

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. 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.

Vehicles with a Direct Shift Gearbox (DSG)

-- Remove the selector lever cable from the ball head and out of the cable bracket. 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 selector lever from the selector shaft 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 .

Continuation for all vehicles

Fig 4: 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.

Vehicles with a Manual Transmission

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

Fig 5: 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 .

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 6: Identifying Vacuum Hose

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

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

Fig 7: 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 8: 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 9: 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 10: 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.