Removing and installing brake master cylinder, hybrid vehicles — VW
Removing and installing brake master cylinder, hybrid vehicles on VW: 25 steps. What to remove, in what order, and what to check after.
On hybrid vehicles on the platform codes listed below (162, AV2), the brake master cylinder is reached by first lifting out the air damper and its hoses. Brake fluid is drawn off from the reservoir with filling and bleeding equipment, and cloths are packed around the engine and gearbox. The warning contact connector and brake light switch connector are released, the brake lines are marked, undone and sealed with plugs, and the reservoir is pulled out after its securing pin is pressed out. The master cylinder is then unbolted from the brake servo. What makes or breaks the refit is the plunger rod sitting correctly in the master cylinder with the seal properly seated, and keeping brake fluid away from mineral oil and paintwork.
🧭 Before you start
Remove the air damper cover, hoses and damper, extract brake fluid and protect the surrounding area with cloths. Disconnect the level warning and brake light switch connectors, mark, unscrew and plug the brake lines, remove the reservoir and unbolt the master cylinder from the servo. Refit with the plunger rod and seal correctly positioned, press the reservoir in on lubricated plugs, and bleed the brake system without overfilling.
Fits: VW Jetta VI (16, 2010–2018); platform code AV2
- Opens: brake fluid
Don't miss
- Mark the brake line positions before removal; do not bend or interchange the lines.
- Seal each opened brake line with a sealing plug straight away.
- Make sure the plunger rod is correctly positioned and the seal properly seated when joining master cylinder and servo.
- Coat the reservoir sealing plugs with brake fluid before pressing the reservoir in.
- Do not reuse drawn-off brake fluid, and keep it away from mineral oils and paintwork.
Written for this job from the workshop steps below · TorqFix editorial.
📋 Procedure
- Unclip cover for air damper (1) upwards from mountings (arrows) and remove it.
- Disconnect air hoses (1) and (2) from air damper (3).
- To do this, press retaining ring (arrows) together on both sides and pull hoses off.
- Pull air damper (1) upwards out of rubber bushes (arrows).
- 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 equipmentVAS 5234.
- ⚠ Never allow brake fluid to come into contact with fluids that contain mineral oils (e.g. oil, petrol, cleaning agents). Mineral oils damage the plugs and seals in the brake system.Brake fluid is poisonous and must never be sucked out by mouth through a hose. Because of its caustic properties, it must also not come into contact with paintwork.Do not reuse drawn-off brake fluid.Always observe the relevant environmental regulations for disposal. — Unclip wiring harness (2) from brake master cylinder (1)(arrows).
- Release connector (1) and pull it off brake fluid level warning contact F34.
- ⚠ Do not bend the brake lines.Do not interchange brake lines when connecting them.Mark installation position before removing brake lines. — Unscrew flare nut of brake line (2).
- Seal brake line with sealing plug1H0 698 311 A.
- Press out securing pin (2) in (direction of arrow).
- Carefully pull brake fluid reservoir (1) out of sealing plug.
- Release connector (1) and pull it off brake light switchF(2).
- Unclip cable retainer from brake master cylinder.
- Unscrew flare nut of brake line (2) from master brake cylinder (1).
- Seal brake line with sealing plug1H0 698 311 A.
- Unscrew and remove threaded connections (arrows) of brake master cylinder (1).
- Carefully take brake master cylinder out of brake servo.
- Carefully remove brake servo from the vehicle.
- Carefully insert brake servo and tighten nuts hand-tight.
- When assembling brake master cylinder with brake servo, make sure plunger rod is properly positioned in brake master cylinder.
- When joining brake master cylinder to brake servo, make sure seal is properly seated.
- Ensure that seals are correctly seated in brake master cylinder.
- Coat sealing plugs with brake fluid before pressing brake fluid reservoir into brake master cylinder.
- Bleed brake system . [Note: Brake fluid must not be filled above MAX marking (1) to prevent brake fluid from running out.]
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The story behind TorqFix →Workshop data on this page last updated 20 Sep 2026.