Brake Master Cylinder, Removing And Installing, RHD Vehicles

WARNING: This page is about a different car, the 2023 Volkswagen Arteon. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Brake Filling and Bleeding Equipment:VAS 6860

Fig 1: Brake Filling and Bleeding Equipment : VAS6860
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Engine Bung Set:VAS 6122

Fig 2: Engine Bung Set
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Torque Wrench 1331 Insert - Ring Wrench - 11mm & 17mm:VAG1331/2
Repair Kit Plugs:1H0 698 311 A

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Plugs assembly part 5Q0 698 311

Fig 3: Plug 5 Q 0 698 311
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Hose Clamps - Up To 25 mm:3094

Fig 4: Hose Clamps
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Socket T30:T10405

Fig 5: Identifying Socket T30
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Removing

-- If equipped, remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

-- Disconnect the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

Hybrid vehicles

-- Observe the safety precautions when working on the high-voltage system. Refer to SAFETY PRECAUTIONS WHEN WORKING ON THE HIGH-VOLTAGE SYSTEM .

-- Pay attention to the high-voltage system danger classification. Refer to the appropriate Service Information .

Vehicles with Diesel Engine:

-- Remove the lines for the Reducing Agent Injector -N474- from the upper toothed belt guard. Refer to the appropriate Service Information .

-- Remove the Reducing Agent Injector -N474- from the emissions control module and move to the side with the lines attached. Refer to the appropriate Service Information .

-- Remove the Differential Pressure Sensor -G505- and the Exhaust Pressure Sensor 1 -G450- from the cylinder head. Refer to the appropriate Service Information .

-- Remove the Exhaust Gas Temperature Sensor 3 -G495-. Refer to EXHAUST GAS TEMPERATURE SENSOR, REMOVING AND INSTALLING, AWD , EXHAUST GAS TEMPERATURE SENSOR, REMOVING AND INSTALLING, FWD .

-- Remove the fuel filter and place it with the fuel hoses connected on the engine. Refer to FUEL FILTER .

Vehicles with Biturbo Diesel Engine

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-- Release and remove the connector -2- on the coolant expansion tank.

-- Unclip, disconnect and remove the connector -4-.

-- Unclip the bracket for the fuel lines on the coolant expansion tank -arrow-.

-- Release the catches with a screwdriver -6-.

-- Place the coolant expansion tank -1- on the engine.

Continuation for All Vehicles:

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-- Disconnect the connector -1-.

-- Remove the bracket -2- with the fuel hoses.

-- Open the bracket and remove the coolant hoses from the engine.

-- Release the retainers with a screwdriver -arrow- and place the coolant expansion tank on the engine.

-- Remove the fuel lines -1- and -2- and move it to the side. Disconnect the couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

Fig 6: Identifying Hose Coupling

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-- Unclip the A/C pipes in the area of the brake booster. Refer to SYSTEM OVERVIEW - REFRIGERANT CIRCUIT .

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-- Unclip the refrigerant lines -1- from the right longitudinal member. Open the bracket -arrows- for this.

-- Release and disconnect the Brake Fluid Level Warning Switch - F34- connector -3- from the brake fluid reservoir -1-.

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-- Unclip the wiring harness -4- from the brake master cylinder.

-- Release and disconnect the connectors -2- and -5-.

Vehicles with a heat shield:

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-- Remove the bolt -4-.

-- Remove and detach the heat shield -3- on the top of the brake fluid reservoir -1- on the mount -2-.

Continuation for All Vehicles:

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-- Place enough lint-free cloths near the engine and subframe.

-- Extract as much brake fluid as possible from the brake fluid reservoir -1- with the Brake Filling and Bleeding Equipment:VAS6860US -A-.

Vehicles with Manual Transmission:

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-- Remove the return hose -4- on the clutch master cylinder -3- and on the brake fluid reservoir -1-.

-- Close off the clutch master cylinder hose -4- using the Engine Bung Set:VAS 6122 or the Hose Clamps - Up To 25mm:3094 .

Continuation for All Vehicles:

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-- Remove the brake lines -1- and -3- on the brake master cylinder -2-.

-- Seal off the threaded holes immediately using the Plugs:1H0 698 311 A or plugs with assembly part number 5Q0 698 311.

-- Seal the brake lines with plugs from the Repair Kit part number 1H0 698 311 A or with the Engine Bung Set:VAS 6122 . If necessary, place the breather valve dust caps on the brake line.

-- Remove the nuts -2-.

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-- Remove the brake master cylinder -1- from the brake booster.

Installing:

Install in the reverse order of removal while noting the following:

-- When assembling the brake master cylinder with the brake booster, make sure that the pushrod is correctly seated in the brake master cylinder.

-- Make sure the seal fits correctly when attaching the brake master cylinder to the brake booster.

-- Bleed the brake system. Refer to HYDRAULIC SYSTEM, STANDARD BLEEDING .

-- Brake system post-bleeding. Refer to HYDRAULIC SYSTEM, POST-BLEEDING .

Vehicles with Manual Transmission:

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-- Check the seals -2- for damage and replace them if necessary.

-- Make sure that the seals -2- are seated correctly in the return hose -4-.

-- Connect the hose -4-.

-- Bleed the clutch mechanism. Refer to the appropriate Service Information .

Continuation for All Vehicles:

-- Perform the electromechanical brake booster basic setting using the Vehicle Diagnostic Tester.

Tightening Specifications

Refer to OVERVIEW - BRAKE BOOSTER/BRAKE MASTER CYLINDER, RHD
Refer to OVERVIEW - AIR ROUTING AND AIR DISTRIBUTION IN VEHICLE INTERIOR .
Refer to the appropriate Service Information .
Refer to the appropriate Service Information .
Refer to OVERVIEW - HEATED OXYGEN SENSOR .
Refer to FUEL FILTER .
Refer to Component Location Overview - A/C System .