Removing and installing brake master cylinder, RHD vehicles

Special tools and workshop equipment required

Torque wrench -V.A.G 1331-

Torque wrench -V.A.G 1410-

Tool inserts (11 mm) -V.A.G 1331/2-

Brake filling and bleeding equipment -VAS 5234-

Sealing plug repair kit -1H0 698 311 A-

Hot air blower, e.g. hot air blower -VAS 1978/14A-

Location:

Make sure not to bend the brake lines in the area of the brake master cylinder.

• Observe safety precautions when working on the high-voltage system → Chapter.
• Observe the risk classification of the high-voltage system → Electric drive; Rep. gr.00.
• Disconnect battery → Electrical system; Rep. gr.27.
• Remove engine cover → Rep. gr.10.

• Disconnect fuel lines -1- and -2- and lay to side. Separate plug-in connectors → Rep. gr.20.

Vehicle with heat shield:

• Remove bolt -1-.
• Detach heat shield -2- at top of brake fluid reservoir -3--arrows-.

Continuation for all models:

• Place sufficient lint-free cloths in area of engine, subframe and gearbox.

• Release and disconnect connector -2- from brake fluid level warning contact -F34- at brake fluid reservoir -1-.
• Draw off as much brake fluid as possible from brake fluid reservoir using brake filling and bleeding equipment -VAS 5234-.

• Mark brake lines -A- and -B- on brake master cylinder.
• Unscrew brake lines -A- and -B- from brake master cylinder.
• Immediately seal brake lines and open connections with sealing plugs from repair kit -1H0 698 311 A- or suitable plugs from engine bung set -VAS 6122-.

• Remove bolts -arrows-.
• Remove brake master cylinder -1- from brake servo.

Installing:

Install in reverse order. Note the following points:

• When assembling brake master cylinder with brake servo, make sure push rod is properly positioned in brake master cylinder.
• When joining brake master cylinder to brake servo, make sure seal is properly seated.
• Bleed brake system → Chapter.
• Subsequently bleeding the brake system → Chapter.
• Perform basic setting for electromechanical brake servo → Vehicle diagnostic tester.

Specified torques

→ Heating, air conditioning system; Rep. gr.87.

→ Rep. gr.87

→ Rep. gr.93

→ Rep. gr.93