Brake Booster, Removing And Installing, With 4-Cylinder Gasoline Engine: Removing
Vehicles with 2.0 L Gasoline Engine and Turbocharger:
-- Remove the engine cover upward from the attaching points -arrows-. Refer to ENGINE COVER, REMOVING AND INSTALLING (CPLA, CPPA, CPKA, CPRA) or ENGINE COVER, REMOVING AND INSTALLING (DDSA, DDSB) .
-- Remove the intake hose -2-. Refer to OVERVIEW - AIR FILTER HOUSING (CPLA, CPPA, CPKA, CPRA) or OVERVIEW - AIR FILTER HOUSING (DDSA, DDSB) .
-- To do this, loosen clamps -1-.
-- Seal the openings with the : VAS6122 .
Continuation for All Vehicles:
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 .
-- Remove bolts -arrows- to remove battery tray. Refer to BATTERY TRAY, REMOVING AND INSTALLING .
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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 .
- 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.
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
-- 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 hose -2-.
-- Remove the selector mechanism from the transmission. Refer to OVERVIEW - SELECTOR MECHANISM .
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
-- 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.
It is not necessary to remove the insulation.
-- Pull the vacuum line -1- out of the brake booster -2-.
-- Disconnect and remove the connector -1- from the Brake Fluid Level Warning Switch -F34-.
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-.
-- Carefully pull the brake fluid reservoir -1- out of the plugs.
-- Unlock and disconnect the connector -1- from the Brake Lamp Switch -F- -2-.
-- Unclip the wiring bracket from the brake master cylinder.
-- Remove the brake line tube fitting -2- from the brake master cylinder -1-.
-- 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.
It is not necessary to loosen the threaded connection -2-.
Continuation for All Vehicles
-- Carefully remove the brake booster from the vehicle.