Removing and installing brake fluid reservoir, left-hand drive vehicle

Special tools and workshop equipment required

• Sealing tool - T10249-

• Brake filling and bleeding equipment - VAS 5234-

Removing:

• Draw off as much brake fluid as possible from brake fluid reservoir using brake filling and bleeding equipment - VAS 5234- and adapter - VAS 5234/1- .
• To protect against escaping brake fluid, place a number of lintfree cloths in area beneath brake master cylinder.

Vehicles with diesel engines

• Free vacuum hose -arrows-.
• Loosen hose clips -1 and 2-, remove ventilation pipe.

Vehicles with 1.8-l and 2.0-l petrol engines

• Loosen hose clips -2 and 3-, remove ventilation pipe.

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 -3- with sealing tool - T10249- - 1-.
• Tie return hose -2- in place above.

Continued for all vehicles

• Unplug electrical connector for brake fluid level warning contact - -F34-- -2-.

• Remove lock pin -1- and pull brake fluid reservoir -2- off the sealing plugs.

Note Push brake line slightly to one side.

Installation:

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

• Lightly lubricate seals with brake fluid before installing brake fluid reservoir.
• Fit brake fluid reservoir.

• Bleed brake system .

Vehicles with manual gearboxes

• Bleed clutch control mechanism .

Removing and installing brake fluid reservoir, right-hand drive vehicle

Special tools and workshop equipment required

• Sealing tool - T10249-

• Brake filling and bleeding equipment - VAS 5234-

Removing:

• Draw off as much brake fluid as possible from brake fluid reservoir using brake filling and bleeding equipment - VAS 5234- and adapter - VAS 5234/1- .
• To protect against escaping brake fluid, place a number of lintfree cloths in area beneath brake master cylinder.

• If present, remove heat shield.
• To do so, remove clamping washer -4- from bulkhead.
• Open snaps -1- to -3- on heat shield.

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

• Remove heat shield -1- if present.
• To do this, unscrew bolt -3-.
• Pull heat shield -1- upwards out of retainers -arrows- on brake fluid reservoir -2-.

• Release electrical connector -2- for brake fluid level warning contact - F34- and pull it off brake fluid reservoir -1-.

• Pull out lock nut -3- in -direction of arrow-.
• Pull brake fluid reservoir -1- upwards off brake master cylinder -2-

• When doing this, gently press refrigerant line -1- upwards.

Installation:

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

• Lightly lubricate seals with brake fluid before installing brake fluid reservoir.
• Fit brake fluid reservoir.

• Bleed brake system .

Vehicles with manual gearboxes

• Bleed clutch control mechanism .