Brake Booster, Removing and Installing

Special tools and workshop equipment required

• Brake Charger/Bleeder Unit -VAS5234-
• Release Tool - Brake Servo -T10159- or Brake Servo Release Tool -T10159A-
• Torque Wrench 1331 5-50Nm -VAG1331-

Removing

• On vehicles with a coded radio, note the code and if necessary retrieve it.
• Disconnect the battery.
• Remove the air filter.
• Remove the battery.
• Remove the battery carrier.
• Open the wiring duct, remove both wiring harnesses and lay them aside.
• Remove the wiring duct from the console.
• Place enough lint-free cloths near the engine and transmission.
• Extract as much brake fluid as possible from the brake fluid reservoir using the Brake Charger/Bleeder Unit -VAS5234-.

For Vehicles with Manual Transmission:

• Disconnect the clutch master cylinder return hose -B- and secure it out of the way or clamp it off with a commercially available tool such as the Hazet 4590 and then remove it.

Continuation for All Vehicles

• Remove the connector -A- from the Brake Fluid Level Warning Switch -F34-.
• Remove the connector -C- from the Brake Lamp Switch -F-.
• Pull the vacuum hose out of the brake booster.
• Mark both brake lines from the brake master cylinder to the hydraulic unit and remove them.
• Immediately seal off the brake lines and the threaded holes with the plugs from Repair Kit -1H0 698 311 A-.

• Remove the nuts -arrows- and remove the foot well trim -1-.
• Remove the noise insulation on the brake pedal, if applicable -item 3-
• Disconnect the brake pedal from the brake booster.

• Remove the nuts -1- from brake booster.
• Loosen both upper nuts -2- from the mounting bracket.
• Carefully remove the brake booster from vehicle.
• Remove the nuts for the brake master cylinder.
• Carefully remove the brake master cylinder from the brake booster.

Installing

• Install in reverse order of removal.

Note the following points when installing:

• Make sure that the boot is installed correctly.
• Clip the brake pedal to the brake booster.
• After removing the bleed the brake system.
• Vehicles with a manual transmission: bleed the clutch system.

Tightening Specifications

Brake booster to pedal assembly/bulkhead 25 N·m

• Use new nuts!

Brake master cylinder to brake booster 25 N·m

• Use new nuts!

Brake lines to brake master cylinder 14 N·m