Removal
Disconnect the battery. Remove the air filter. Remove the battery. Remove the battery bracket. Open the wiring box, remove both wire harnesses and put them to one side. Remove the wiring box from the console. Cover the engine and gearbox with a lint-free cloth. Using the device -VAS 5234- or -VAG 1869/4-, pump out as much brake fluid as possible from the expansion tank.
With manual transmission
Disconnect hose "B" from the clutch master cylinder and tie it up.
All
Disconnect connector "A" from brake fluid level sensor "F34". Disconnect connector "C" from brake light switch "F". Disconnect vacuum hose from brake booster. Mark position and disconnect both brake pipes connecting master cylinder and hydraulic unit. Immediately close pipes and threaded holes with plugs from set 1 NO 698 311 A.
Additional work for cars with 1.4 l FSI engine
Remove the control unit and hydraulic block.
Additional work for cars with 2.0 l TDI engine
Move aside and secure the hose connecting the air filter to the turbocharger. Loosen the screw clamp on the hose connecting the boost tube to the turbocharger and turn the clamp back.
All
Loosen the nuts "arrows" and remove the footwell trim "1". Remove the sound insulation (if any) from the brake pedal. Disconnect the brake pedal from the brake booster. Loosen the nuts "1" securing the brake booster. Loosen the two upper nuts "2" securing the support bracket. Carefully remove the brake booster from the vehicle. Loosen the nuts securing the master brake cylinder. Carefully disconnect the master brake cylinder from the brake booster.
Installation
Installation is carried out in the reverse order. Make sure that the cuff is seated correctly. Install the brake booster rod into the brake pedal socket. After installation, bleed the brake system and clutch hydraulic drive.
Tightening torques
| Brake booster to pedal assembly/engine compartment bulkhead, use new nuts only! | 25 Nm |
| Master cylinder to brake booster, use only new nuts! | 25 Nm |
| Brake lines to the master cylinder | 14 Nm |
(The text is copied from this portal: VWmanual)
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