Master Brake Cylinder, 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

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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 procedure.

-- Remove the intake hose -2-. Refer to OVERVIEW - AIR FILTER HOUSING (CPLA, CPPA, CPKA, CPRA) or OVERVIEW - AIR FILTER HOUSING (DDSA, DDSB) .

Fig 2: Air Filter, Assembly Over View

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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 .

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 3: Identifying Brake Charger/Bleeder Unit VAS5234

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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.

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

Fig 4: Removing Brake Master Cylinder

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-- 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.

Vehicles with Manual Transmission

Fig 5: 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 : VAS6122 -1-.

-- Tie up the hose -2-.

Continuation for All Vehicles

Fig 6: Identifying Connector & Warning Switch

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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.

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

-- Remove the brake line pipe fitting -2-.

-- Seal the brake line with Plugs.

-- Carefully pry the brake fluid reservoir -1- off the retaining tabs -arrows- on the brake master cylinder -2-.

Fig 7: Identifying Brake Fluid Reservoir

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-- 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

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-- 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

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-- Seal the brake lines with the Plugs.

-- Remove the nuts -arrows- on the brake master cylinder -1-.

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