Volkswagen Workshop Service and Repair Manuals

Removing –  Note or request radio code on vehicles with coded radio if necessary. –  Disconnect battery. → Electrical system; Rep. gr.27. Vehicles with diesel engine:

–  Disconnect wiring connector -1- and loosen rear spring-type clip on intake hose.

–  Loosen spring-type clip -arrow- and pull hose off air cleaner housing

–  Remove securing bolt from air cleaner housing -arrow-. –  Pull air filter housing upwards out of brackets and remove it. Continuation for all models: –  Removing and installing → Electrical system; Rep. gr.27 –  Remove battery tray. –  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 equipment -VAS 5234- or extraction unit -V.A.G 1869/4-. Vehicles with manual gearbox:

–  Detach supply hose -B- for clutch master cylinder, lift clear and tie in place, or clamp off supply hose -B- for clutch master cylinder with a commercially available tool, e.g. Hazet 4590, and then pull off. Continuation for all models: –  Pull connector -A- off float warning indicator sender. –  Separate connector from brake light switch -F- (vehicles from week 45/2005 only).

–  Remove brake fluid reservoir. To do this press locking tabs on reservoir outwards and simultaneously pull brake fluid reservoir out of sealing plugs. –  Disconnect brake lines -1- on brake master cylinder and seal brake lines with plugs from repair kit Part No. 1H0 698 311 A. –  Remove nuts -2- from brake master cylinder. –  Remove heat shield (if installed). –  Carefully take brake master cylinder out of brake servo. –  Pull vacuum hose out of brake servo. Vehicles with manual gearbox:

–  Release cables -1-, unbolt support bracket -2- and place it to side → Rep. gr.34. Continuation for all models: –  Remove trim on driver side → General body repairs, interior; Rep. gr.70 From week 45/2005, the brake light switch is no longer located on the mounting bracket.

–  Pull connector -1- off brake light switch. –  Remove brake light switch -2- by turning 45° to left. –  Remove air duct -3-. –  Remove cover -4-. –  Separate brake pedal from brake servo → Chapter.

–  Unscrew nuts -1- from brake servo. –  Remove both upper nuts -2- from mounting bracket. –  Carefully remove brake servo from vehicle.