Removing and installing brake master cylinder, LHD

Special tools and workshop equipment required

• Torque wrenches - V.A.G 1331-

• Brake filling and bleeding equipment - VAS 5234-

Removing:

• Remove the brake fluid reservoir.
• Remove brake light switch - F-.
• Disconnect brake lines -1- from brake master cylinder and seal brake lines with plugs from repair kit.
• Unscrew securing nuts -2- for brake master cylinder.

Note A heat shield is fitted on the brake master cylinder on some models.

• Detach heat shield if fitted.
• Detach brake master cylinder from brake servo.
• Remove brake master cylinder from vehicle.

Installation:

Note Before assembly, install the brake light switch - F- in the brake master cylinder.

• Install brake light switch - F-

• Replace the seal between the brake master cylinder and the servo brake.
• When fitting the brake master cylinder, ensure that the control rod in the servo brake seats correctly.
• Put on new nuts -2- and tighten to required torque.

Note A heat shield is fitted on the brake master cylinder on some models.

• Connect brake lines -1- to brake master cylinder. Note tightening torque.
• Install heat shield if previously removed.
• Connect the electric connector to the brake light switch - F- .
• Install brake fluid reservoir.

Note Plug in electrical connector for brake fluid level warning contact - -F34-- .

Note

• The brake light switch - F- does not have to be calibrated.
• Before the first journey, check that the brake light switch - F- is functioning without fault.

• Bleed brake system

Vehicles with clutch

• Bleeding clutch hydraulics system

Tightening torques:

• Tightening torques for heat shield nuts: 20 Nm

Removing and installing brake master cylinder; RHD

Note If there are problems with the brake servo, first check the brake servo vacuum system

Special tools and workshop equipment required

• Torque wrenches - V.A.G 1331-

• Brake filling and bleeding equipment - VAS 5234-

Fitting location of brake servo in RHD vehicles:

1. - Brake servo and brake master cylinder
2. - ABS hydraulic unit - N55- and ABS control unit - J104-

Removing:

• Remove brake light switch - F-

Vehicles with air conditioning

• Drain air conditioning system .
• Unscrew nuts -2- on refrigerant line -1-.
• Remove refrigerant line -1-.

Continued for all vehicles

• Remove the brake fluid reservoir.

• Removing brake lines -2- on master brake cylinder -1-.
• Seal brake pipes with sealing plugs from repair kit Part No. 1H0 698 311 A.
• Unscrew nuts - arrows -.
• Remove heat shield -3-.
• Carefully remove brake master cylinder from brake servo.

Installation:

Carry out installation in the reverse sequence, noting the following:

• When assembling brake master cylinder with brake servo, make sure plunger rod is properly positioned in brake master cylinder.
• When assembling brake master cylinder with brake servo, make sure seal is properly seated.
• Ensure that seals are correctly seated in brake master cylinder.
• Moisten sealing plugs with brake fluid before pressing brake fluid reservoir into brake master cylinder.
• Bleed brake system

Vehicles with manual gearboxes

• Bleed clutch control mechanism .

Vehicles with air conditioning

• Top up coolant .

Tightening torques:

• Front bleed valves
• Rear bleed valves