Removing and installing brake master cylinder, left-hand drive

Special tools and workshop equipment required

• Brake filling and bleeding equipment - VAS 5234-

• Torque wrench - V.A.G 1331-

6.1.1 Removing

• Note or request radio code on vehicles with coded radio if necessary.
• Disconnect battery. ⇒ Electrical system; Rep. gr. 27; Disconnecting and reconnecting battery.

• Remove air filter housing (except 4-cylinder injection engine, 1.4 l).
• Disconnect connector -A- from brake fluid level warning contact - F34-.
• Separate connector -C- from brake light switch - F-.
• Place sufficient lint-free cloths in area of engine and gearbox.
• Draw off as much brake fluid as possible from brake fluid reservoir using brake filling and bleeding equipment - VAS 5234- or extraction unit -V.A.G 1869/4-.

Additional work for vehicles with manual gearbox:

• Detach supply hose -B- for clutch master cylinder, lift clear and tie in place, or clamp off supply hose -B- for clutch master cylinder with a commercially available tool, e.g. Hazet 4590, and then pull off.

Continuation for all models:

• Push brake fluid reservoir pin through fastening tab and brake master cylinder.
• Then pull brake fluid reservoir out of brake master cylinder.

• Mark and unscrew brake lines from brake master cylinder -1- and immediately seal brake lines with plugs from repair kit Part No. 1H0 698 311 A.
• Remove nuts -2- from brake master cylinder.
• Carefully take brake master cylinder out of brake booster.
• Remove brake light switch - F-.

6.1.2 Installing

• Install in reverse order.

Observe the following important points when installing:

• When assembling brake master cylinder with brake booster, make sure plunger rod is properly positioned in brake master cylinder.
• Bleed brake system ⇒ 4 Bleeding brake system.

Specified torques:

Brake master cylinder to brake booster

25 Nm

• Use new nuts!

Brake lines to brake master cylinder

14 Nm

Torx bolt for brake light switch to brake master cyl‐ 7 Nm inder