Brake Master Cylinder, Removing And Installing, LHD With 5-Cylinder Gasoline Engine: Removing

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

Fig 1: Disconnecting Connector And Intake Hose

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Open the clamp -2- and disconnect the intake hose.

-- If equipped, disconnect the connector -1- and remove.

-- Remove the bolts -3- and the intake hose.

-- Pull the engine with a jerk out of the fasteners first at the front -arrow 1-, then at the right rear -arrow 2- and finally at the left rear -arrow 3-.

Fig 2: Identifying Removal Of Engine Cover With Jerk Out Of Mount First

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Carefully swivel the engine cover out of rear area.

NOTE:

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

-- Remove the battery. Refer to BATTERY, 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 Brake Charger/Bleeder Unit: VAS5234 .

Fig 3: 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 oils damage 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.

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

Fig 4: Removing Brake Master Cylinder

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Release and remove the connector.

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

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

Vehicles with Manual Transmission

Fig 5: 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 Engine Bung Set: VAS6122 -1-.

-- Tie up the hose -2-.

Continuation for All Vehicles

Fig 6: Identifying Connector & Warning Switch

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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 off the brake line with the Plug.

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

Fig 7: 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 8: 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 9: Identifying Master Brake Cylinder

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Seal off the brake line with the Plugs.

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

-- Carefully remove the brake master cylinder from the brake booster.