Removing and installing brake booster, LHD — VW

🧭 Before you start

Fits: platform code AJ5

• Opens: brake fluid
• Special tools named: V.A.G 1869/4

Don't miss

• Disconnect connector (A) from brake fluid level warning contact.
• After installing, bleed brakes and clutch 34.

📋 Procedure

1. If vehicle has a coded radio, note radio code or, if necessary, request it.
2. Place sufficient lint-free cloths in area of engine and gearbox.
3. Draw off as much brake fluid as possible from brake fluid reservoir using brake filling and bleeding equipmentVAS 5234 or extraction unit V.A.G 1869/4.
4. Remove engine cover panel 10Engine cover; Removing and installing engine cover panel.
5. Remove battery Electrical system27Removing and installing batteries.

6. Remove air filter 24Air filter; Assembly overview - air filter housing.
7. If necessary, remove intake hose 24Air filter; Assembly overview - air filter housing.
8. Remove air filter 23Air filter; Assembly overview - air filter housing.
9. If necessary, remove intake hose 23Air filter; Assembly overview - air filter housing.
10. Remove battery tray Electrical system27Battery; Removing and installing battery tray.
11. Clamp off supply hose (B) for clutch master cylinder with hose clamps, up to Ø 25 mm3094.
12. Detach supply hose (B) for clutch master cylinder.
13. Disconnect connector (A) from brake fluid level warning contact.
14. Separate connector (C) from brake light switchF.
15. Release connector (1) from brake light switchF, and pull off connector.
16. Remove brake fluid reservoir .
17. At the same time, pull brake fluid reservoir out of sealing plugs.
18. Disconnect brake lines (1) from brake master cylinder and seal brake lines using sealing plugs1H0 698 311 A.
19. Undo nuts (2) on brake master cylinder.
20. Remove heat shield (if installed).
21. Carefully remove brake master cylinder from brake booster.
22. Pull out vacuum hose from brake booster.
23. Release cables (1), then unbolt cable support bracket (2) and lay it to one side 34Repairing selector mechanism.
24. Remove gear selector cable from ball head and cable support 7-speed dual clutch gearbox 0AM34Selector mechanism.
25. Remove selector lever from selector shaft on gearbox 7-speed dual clutch gearbox 0AM34
26. Remove cover in driver footwell General body repairs, interior68Compartments, covers and trims.
27. Separate brake pedal from brake booster .
28. Unscrew nuts (1) from brake booster.
29. Carefully remove brake booster from the vehicle.
30. If brake booster sticks in holes, loosen both upper nuts (2) on mounting bracket.
31. Install in reverse order.
32. Clip brake pedal to brake booster .
33. Install and connect battery Electrical system27.
34. After installing, bleed brakes and clutch 34.

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