Removing and installing brake master cylinder, LHD vehicles with 5-cyl. petrol engine — VW

🧭 Before you start

Fits: VW Jetta VI (16, 2010–2018); platform code AV2

• Opens: brake fluid, clutch fluid

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• Disconnect battery earth strap for all further work. Before doing so, check whether a coded radio is fitted in the vehicle. If there is one, first find out what the anti-theft code is.
• There is a danger of electronic components being destroyed when battery is disconnected.Take necessary measures before disconnecting battery. — Place sufficient lint-free cloths in area of engine and gearbox.
• 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).
• When assembling brake master cylinder with brake servo, make sure plunger rod is properly positioned in brake master cylinder.

📋 Procedure

1. Open clamp (2) and pull off intake hose.
2. If fitted, release connector (1) and pull it off.
3. Remove bolts (3) and pull off intake hose.
4. To detach engine cover from its fastenings, jerk it upwards first at the front (arrow 1) and then at the rear on the right (arrow 2) and finally at the rear on the left (arrow 3).
5. Carefully swivel engine cover out of the rear area. [Note: Disconnect battery earth strap for all further work. Before doing so, check whether a coded radio is fitted in the vehicle. If there is one, first find out what the anti-theft code is.]

6. Remove battery Electrical system27Battery; Removing and installing battery.
7. ⚠ There is a danger of electronic components being destroyed when battery is disconnected.Take necessary measures before disconnecting battery. — Place sufficient lint-free cloths in area of engine and gearbox.
8. Draw off as much brake fluid as possible from brake fluid reservoir using brake filling and bleeding equipmentVAS 5234.
9. ⚠ 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. — Remove star fasteners (arrows).
10. Release electrical connector and pull off.
11. Unclip connector and wiring harness from plenum chamber bulkhead.
12. Fold insulation (1) for bulkhead forwards in (direction of arrow) and remove it carefully.
13. Pull return hose (2) for clutch sender cylinder (3) off brake fluid reservoir (4).
14. Seal return hose (2) for clutch master cylinder (3) with sealing tool T10249(1) or engine bung setVAS 6122.
15. Raise and tie return hose (2) in place.
16. Release connector (1) and pull it off brake fluid level warning contact F34.
17. ⚠ 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).
18. Seal brake line with sealing plug1H0 698 311 A.
19. Press out securing pin (2) in (direction of arrow).
20. Carefully pull brake fluid reservoir (1) out of sealing plug.
21. Release connector (1) and pull it off brake light switchF(2).
22. Unclip cable retainer from brake master cylinder.
23. Unscrew flare nut of brake line (2) from master brake cylinder (1).
24. Seal brake lines with sealing plugs1H0 698 311 A.
25. Unscrew and remove threaded connections (arrows) of brake master cylinder (1).
26. Carefully take brake master cylinder out of brake servo.
27. When assembling brake master cylinder with brake servo, make sure plunger rod is properly positioned in brake master cylinder.
28. Bleed brake system .
29. Bleed clutch 30Clutch mechanism; Bleeding clutch mechanism.
30. Install and connect battery Electrical system27Battery; Removing and installing battery.
31. When fitting engine cover, make sure that rubber buffers are correctly inserted in mountings. [Note: Brake fluid must not be filled above MAX marking (1) to prevent brake fluid from running out.]

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