Audi Workshop Service and Repair Manuals

Removing and installing brake servo Removing Special tools and workshop equipment required t  Torque wrench -V.A.G 1331- t  Adapter -VAS 5234/1- t  Brake filling and bleeding equipment -VAS 5234- t  Sealing plug repair kit, Part No. -1H0 698 311 A- –  Switch off engine. –  Press brake pedal repeatedly („pump the brake servo dry“) until there is no more servo assistance and the brake pedal is heavy.

–  Remove driver's storage compartment -1 ... 3-.

–  Unplug electrical connector -C- on footwell vent. –  Remove footwell vent -A-B-. –  Remove brake light sensor → Chapter. –  Separate brake pedal from brake servo → Chapter. –  Detach engine cover panel. –  Remove plenum chamber cover → Rep. gr.50. –  Remove body brace → Rep. gr.40. –  Remove plenum chamber partition panel → Rep. gr.50. –  Remove brake fluid reservoir → Chapter.

–  Unscrew nuts -3- for brake master cylinder → Chapter. –  Remove brake master cylinder from vehicle. –  Put down brake master cylinder so that no brake fluid can escape.

–  Detach vacuum line -3- from brake servo.

–  Remove bolts -1- securing brake servo to mounting bracket. –  Remove brake servo from vehicle. Installing –  Fit brake servo in vehicle. Ensure that seal is seated correctly.

–  Install and tighten bolts -1- securing brake servo to mounting bracket.

–  Push vacuum line -3- into brake servo. –  Install brake master cylinder → Chapter. –  Install brake fluid reservoir → Chapter. –  On vehicles with manual gearbox, attach hydraulic line -5- for clutch to brake fluid reservoir.

–  Fill up brake fluid as far as mark. –  Bleed brake system → Chapter. –  On vehicles with manual gearbox, bleed clutch → Rep. gr.30. –  Install plenum chamber partition panel → Rep. gr.50. –  Install body brace → Rep. gr.40. –  Install engine cover panel. –  Install plenum chamber cover → Rep. gr.50. Attaching brake pedal to brake servo –  Hold ball head of push rod in front of mounting and push brake pedal towards brake servo so that ball head audibly locks into place. –  Install brake light sensor → Chapter.

–  Install footwell vent -A-. –  Plug in electrical connector -C- on footwell vent.

–  Install driver's storage compartment -1 ... 3-.