Brake Booster, Removing And Installing, With 4-Cylinder Diesel Engine: Removing

WARNING: This page is about a different variant/trim than selected.

-- Remove engine cover near in direction of -arrows-.

Fig 1: Engine Cover

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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 OVERVIEW - AIR FILTER HOUSING (CPLA, CPPA, CPKA, CPRA) or OVERVIEW - AIR FILTER HOUSING (DDSA, DDSB) .

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

Fig 2: Air Duct Cover Slide Clips

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Release the left and right clips in direction of -arrow A- and unclip the lower air guide -2-.

Fig 3: Disengaging Lower Air Guide

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

-- Disengage the air duct pipe -1- from the lower air duct in direction of -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 -1-, Vacuum Line -2-, Bolt -3- And Clamp -4-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

-- Seal all openings using the : VAS6122 .

NOTE:

The battery ground cable must be disconnected for the following procedure. Check if a coded radio is installed. If necessary, obtain anti-theft code beforehand.

-- Remove the battery. Refer to BATTERY, REMOVING AND INSTALLING .

Fig 5: Identifying Battery Housing Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove bolts -arrows- to remove battery tray. Refer to BATTERY TRAY, REMOVING AND INSTALLING .

CAUTION:

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

Follow the steps for disconnecting the battery.

-- Place enough lint-free cloths near the engine and transmission.

-- Extract as much brake fluid as possible from the brake fluid reservoir using : VAS5234 .

Fig 6: Identifying Brake Charger/Bleeder Unit VAS5234

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

WARNING:

Brake fluid must never come into contact with fluids containing mineral oils (oil, gas, cleaning solutions). Mineral oil damages the brake system plugs and boots.
Brake fluid is poisonous, and must never be siphoned by mouth under any circumstances. Also due to its corrosive effect, brake fluid must not come into contact with paintwork.
Extracted brake fluid cannot be used again.
Follow all disposal regulations.

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

Fig 7: Identifying Release Buttons

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the connector from the crankcase 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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Unclip and remove the intake tube -1- for the preheater on the bracket.

-- Remove the bolt -arrow-.

Fig 9: Identifying Intake Tube

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

Vehicles with Emissions Control Module:

Fig 10: Identifying Bolts, Clamp & Air Guide Pipe

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the bolts -arrows-.

-- Loosen the clamp -2- and remove the air duct pipe -1-.

Vehicles with DSG^® Transmission

-- Remove the selector lever cable from the ball head and out of the cable bracket. Refer to OVERVIEW - SELECTOR MECHANISM .

-- Remove the selector lever from the selector shaft on the transmission. Refer to OVERVIEW - SELECTOR MECHANISM .

Vehicles with Manual Transmission

Fig 11: Identifying Supply Hose

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Seal the hose -2- for the clutch master cylinder -3- with the : VAS6122 -1-.

-- Tie up the return hose -2-.

-- Remove the selector mechanism from the transmission. Refer to the appropriate service information .

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Release and remove the connector.

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

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

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 14: Identifying Connector & Warning Switch

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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 pipe fitting -2-.

-- Seal the brake line with Plugs.

-- Remove the fastening pin -2- in direction of -arrow-.

Fig 15: Identifying Brake Fluid Reservoir

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Carefully pull the brake fluid reservoir -1- out of the plugs.

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

Fig 16: Identifying Brake Line Tube Fitting

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

Fig 17: Identifying Master Brake Cylinder

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Seal the brake line with Plugs.

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

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

-- Disconnect the brake pedal from the 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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

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

Continuation for All Vehicles

-- Carefully remove the brake booster from the vehicle.