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

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

Vehicles with 2.0 L Gasoline Engine and Turbocharger:

Fig 1: Identifying Engine Cover Attachment Points

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-- 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) .

Fig 2: Air Filter, Assembly Over View

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-- To do this, loosen clamps -1-.

-- Seal the openings with the : VAS6122 .

Continuation for All Vehicles:

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.

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 .

Continuation for All Vehicles

Fig 4: Removing Brake Master Cylinder

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-- 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.

Vehicles with Manual Transmission

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

Fig 5: Identifying Supply Hose

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-- 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 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 6: Identifying Vacuum Hose

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-- 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-.

Fig 7: 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.

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

-- Seal the brake line with Plugs.

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

Fig 8: 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 9: 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 10: Identifying Master Brake Cylinder

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-- 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.