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

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

Fig 1: Identifying Brake Charger/Bleeder Unit VAS5234

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-- Place enough lint-free cloths in the engine area.

-- Extract as much brake fluid as possible from the brake fluid reservoir using Brake Filling and Bleeding Equipment: VAS 6860 .

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 waste disposal regulations.

-- Remove the noise insulation. Refer to NOISE INSULATION, REMOVING AND INSTALLING .

-- Remove engine cover near the -arrows-.

Fig 2: Engine Cover

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-- Observe the given sequence -1- through -4-.

-- Reach under the engine cover as far as possible.

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 instruction.

-- Remove the heat shield -1- from the diesel particulate filter to do so remove the nuts -arrows-.

Fig 3: Locating Heat Shield Nuts

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-- Release and remove the bracket -1- from the toothed belt guard.

Fig 4: Identifying Particulate Filter Mount

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Vehicles with 2.0L diesel engines

Fig 5: Identifying Oil Pressure Connector, Bolt And Bracket

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-- Disconnect the connector -1- from the Oil Pressure Switch --.

-- Remove the screw -2-.

-- Push the bracket -3- for the Differential Pressure Sensor -- in the -direction of the arrow- from the guide.

-- Move the bracket -3- with the lines still attached to the side.

-- Release and disconnect the connector -1-.

Fig 6: Identifying Connector, Fuel Lines, Bracket And Washer Fluid Hose

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-- Unclip the fuel lines -2- from the bracket -3-.

-- Unclip the washer fluid hose -4- from the bracket -3-.

-- Open the couplings -A- and -B- and remove the fuel lines. Disconnect the couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

Fig 7: Identifying Fuel Line Couplers

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WARNING:

The fuel line is under pressure.

Fuel poses a risk of injury to the eyes and skin.

Wear protective eyewear and protective clothing to avoid injury and contact with skin. Place a cleaning cloth around the connection point before loosening hose connections. Carefully open the connection point to release the pressure.

-- Move the fuel lines to the side.

-- Remove the bolts -arrows-.

Fig 8: Identifying Bolts

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-- Move the Auxiliary Fuel Pump -V393- or Fuel Pump 2 -V277- -1- with the lines still attached to the side.

Vehicles with 1.6L diesel engines

Fig 9: Identifying Fuel Line Couplers

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-- Open the couplings -A- and -B- and remove the fuel lines. Disconnect the couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

WARNING:

The fuel line is under pressure.

Fuel poses a risk of injury to the eyes and skin.

-- Unclip and free up the fuel lines.

-- Move the fuel lines to the side.

-- Disconnect and remove the connector -3- from the Differential Pressure Sensor -- -4-.

Fig 10: Identifying Connector And Differential Pressure Sensor

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-- Unclip the hoses -2- from the retainer.

-- Remove the bolts -1-.

-- Set the Differential Pressure Sensor -- -4- with lines attached to the side.

-- Move the fuel lines to the side.

-- Remove the bolts -arrows-.

Fig 11: Identifying Bolts

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-- Move the Auxiliary Fuel Pump -V393- or Fuel Pump 2 -V277- -1- with the lines still attached to the side.

Continuation for All Vehicles

Fig 12: Identifying Connector And Coolant Expansion Tank

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-- Release and remove the connector -1- from the coolant expansion tank -2-.

-- Unclip the wire -4- from the coolant expansion tank -2- and set aside.

-- Remove the bolts -3- and the coolant expansion tank -2-.

-- Move the coolant expansion tank upward and set aside.

-- Open the clips -arrows- and remove the upper toothed belt cover.

Fig 13: Removing Upper Toothed Belt Guard

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-- Disconnect the connector -1- from the Brake Fluid Level Warning Switch -F34- -2-.

Fig 14: Identifying Connector And Brake Fluid Level Warning Switch

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-- Disconnect and remove the connector -A- from the Brake Lamp Switch -F-.

Fig 15: Identifying Connector And Brake Lamp Switch

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-- Remove the securing plate -arrows- and fold the noise insulation -1- forward.

Fig 16: Identifying Securing Plate And Noise Insulation

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Vehicles with Manual Transmission:

Fig 17: Identifying Supply Hose

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-- 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-.

-- Remove the brake lines -3- on the master brake cylinder -1-.

Fig 18: Identifying Brake Lines And Master Brake Cylinder

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CAUTION:

Brake lines must not be bent.

Do not confuse the brake lines when connecting them.

Mark the lines in their installed position before removing them.

-- Seal the brake lines with sealing plugs from the Repair Set.

-- Remove the nut -2-.

-- Pull the vacuum line -4- out of the brake booster -1-.

-- Remove the heat shield, if equipped.

-- Remove the nut -1-.

Fig 19: Identifying Connector And Brake Lamp Switch

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-- Carefully take the brake master cylinder -2- out of the brake booster.