Master Brake Cylinder, With 5-Cylinder Gasoline Engine: Installing

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.

Install in reverse order of removal. Note the following:

-- When installing together the brake master cylinder and brake booster, make sure that the push rod is correctly located in the brake master cylinder.

Coat the plugs with brake fluid before pushing the brake fluid reservoir into the master brake cylinder.

-- Bleed the brake system. Refer to DESCRIPTION AND OPERATION .

Vehicles With A Manual Transmission

-- Bleed the clutch. Refer to [For transmission(s) 0A4] Diagnosis and Testing or [For transmission(s) 02Q] [For engine(s) CVCA, CPLA, CJAA, CPPA, CCTA, CBFA] Diagnosis and Testing .

Continuation For All Vehicles

-- Install and connect 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 .

-- Make sure the rubber buffers fit correctly in the mounts when installing the engine cover.

Fig 1: Identifying Correct Installation Of Rubber Insulators

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CAUTION: Make sure the 4 fasteners (ball sockets) are positioned correctly before installing the engine cover. Move them into their correct position, if necessary. Otherwise the engine cover will be damaged.

NOTE: To prevent the brake fluid from overflowing from the reservoir, the level must not be over the MAX mark -1-.

Fig 2: Identifying Brake Fluid Level Marks On Reservoir

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.