Removing and installing brake master cylinder, right-hand drive vehicle

Special tools and workshop equipment required

• Sealing tool - T10249-
• Torque wrench - V.A.G 1331-
• Brake filling and bleeding equipment - VAS 5234-

6.2.1 Removing

• Release connector -2- and pull off.
• Undo and remove bolted joint -3-.
• Place coolant expansion tank -1- to one side.

• Detach fuel lines -arrows- at separating point on wheel housing on right and place to one side.
• 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-.
• Place sufficient lint-free cloths in area of engine.

Vehicles with manual gearboxes:

• Pull return hose -2- for clutch sender cylinder -3- off brake fluid reservoir -4-.
• Seal return hose -2- for clutch sender cylinder -3- with sealing tool - T10249- -1-.
• Tie return hose -2- in place above.

Continuation for all models:

• Release and pull connector -1- off brake fluid level warning contact - F34-.

• Unscrew bolt -arrows- from brake fluid reservoir -1-.
• Carefully pull brake fluid reservoir out of sealing plugs of brake master cylinder.

• Mark and unscrew brake lines -1- from brake master cylinder -2-.
• Seal brake lines with sealing plugs - 1H0 698 311 A-.
• Pull vacuum line -3- out of brake booster unit and put it down somewhere.

• Unscrew nuts -arrows- from brake master cylinder -1-.
• Carefully remove brake master cylinder together with brake light switch - F- from brake booster.
• Release and pull connector off brake light switch - F-.
• Remove brake light switch - F-.

6.2.2 Installing

Install in reverse order. Note the following points:

• When assembling brake master cylinder with brake booster, make sure plunger rod is properly positioned in brake master cylinder.

Coat sealing plugs with brake fluid before pressing brake fluid reservoir into brake master cylinder.

• Bleed brake system ⇒ 4 Bleeding brake system.

Specified torque