Removing
Remove the upholstery on the driver's side.
Remove the brake light switch/brake pedal switch.
Remove the brake light switch holder.
Disconnect the brake pedal from the brake booster.
Remove the support on the bracket through which the booster push rod passes (pic. 6.16).
Remove the plenum box cover.
Remove the engine compartment seal and the bar in the area of the brake booster.
Remove the wall from the drainage box.
Remove the plug from the brake pressure sensor.
Remove the plug from the float warning indicator sensor.
Unscrew the wire «mass» from the point «masses» on the body behind the electrical box, remove the cable harness behind the brake booster from its holder and set it aside.
Remove the switching unit on the left side of the plenum box from the holder and lay it as far to the side as possible (pic. 6.17).
Place a sufficient amount of lint-free rags in the plenum chamber in the area of the master cylinder.
Extract the maximum amount of brake fluid using the filling and bleeding device VAS 5234 or the filling and bleeding device VAG 1869/4 from the brake fluid reservoir.
On vehicles with a manual transmission, remove the clutch master cylinder hose and plug it.
Remove the brake fluid reservoir. To do this, press out the latches on the tank and at the same time remove the tank from the plug.
Remove the front left brake line from the holder on the master brake cylinder.
Unscrew the brake pipes from the main brake cylinder, close the brake pipes with plugs 1H0 698 311 A.
Loosen the nuts on the brake master cylinder.
Carefully remove the brake master cylinder from the brake booster.
Remove the diaphragm travel potentiometer.
Remove the vacuum hose from the brake booster.
Remove the brake pipes from the triple holder on the brake booster.
Disconnect the brake pipe at the front left in the wheel housing at the front left.
Loosen the nuts on the brake booster (pic. 6.18).
Carefully remove the brake booster from the plenum box.
Installation
Installation is carried out in the reverse order.
NOTE: Hold the push rod ball head before attaching and depress the brake pedal towards the brake booster until the ball head clicks into place with an audible click.
After installation, bleed the brake system and clutch.
After bleeding the brake system, the basic setting of the brake pressure sender G201 must be carried out.
Connect VAS 5051 and select function.
Adjust the brake signal sensor/brake pedal switch.
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