Removing
Disconnect battery. Remove air filter. Remove the battery. Remove battery bracket. Open the wiring box, remove both wiring harnesses and set them aside. Remove wiring box from console. Close the engine and the box is handed over with a lint-free cloth. Extract the maximum amount of brake fluid from the reservoir using the tool -VAS 5234- or -VAG 1869/4-.
With manual transmission
Disconnect hose -B- from clutch master cylinder and tie it up.
All
Disconnect connector -A- from brake fluid level sender -F34-. Disconnect connector -C- from brake light switch -F-. Disconnect the vacuum hose from the brake booster. Mark the position and disconnect both brake pipes connecting the brake master cylinder and the hydraulic unit. Seal pipes and tapped holes immediately with plugs from set 1 NO 698 311 A.
Additional work for vehicles with 1.4l FSI engine
Remove control unit and hydraulic unit.
Additional work for vehicles with 2.0l TDI engine
Lay aside and secure the hose connecting the air filter and turbocharger. Loosen the screw clamp on the hose connecting the charge air pipe and the turbocharger and turn the clamp back.
All
Remove nuts -arrows- and remove footwell trim -1-. Remove soundproofing (if there) brake pedals. Disconnect the brake pedal from the brake booster. Remove nuts -1- for brake booster. Loosen the top two nuts -2- of the support bracket. Carefully remove the brake booster from the vehicle. Unscrew the nuts securing the brake master cylinder. Being careful, disconnect the brake master cylinder from the brake booster.
Installation
Installation is carried out in the reverse order. Make sure the cuff fits correctly. Install the brake booster rod into the brake pedal socket. After installation, bleed the brake system and hydraulic clutch.
Tightening torques
Brake booster to pedal assembly/engine compartment bulkhead, use new nuts only! | 25 Nm |
Brake master cylinder to brake booster, use new nuts only! | 25 Nm |
Brake pipelines to the main brake cylinder | 14 Nm |
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