VW Golf manuals

Volkswagen Golf Service & Repair Manual: Assembly overview - brake servo/brake master cylinder, LHD vehicles

  Note
Only use new brake fluid conforming to VW standard (VW 501 14).
   

Assembly overview - brake servo/brake master cylinder, LHD vehicles

1 -  Self-locking hexagon nut
Always renew after removing
Bolting sequence → Fig.
25 Nm
2 -  Pedal cluster with mounting bracket
3 -  Plenum chamber bulkhead
4 -  Self-locking hexagon nut
Always renew after removing
23 Nm
5 -  Brake master cylinder
Cannot be repaired. If faulty, renew as a complete unit.
Removing and installing → Chapter
6 -  Brake light switch -F-
Removing and installing → Chapter
7 -  Bolt
8 Nm
8 -  Brake line
From secondary piston circuit of brake master cylinder to hydraulic unit.
14 Nm
9 -  Brake line
From primary piston circuit of brake master cylinder to hydraulic unit.
14 Nm
10 -  Sealing plug
Moisten with brake fluid and press into brake fluid reservoir.
11 -  Brake fluid level warning contact --F34--
12 -  Brake fluid reservoir
Securing bolt, 8 Nm
13 -  Vacuum hose
With non-return valve
Fit in brake servo
On some vehicles with petrol engines, vacuum sender -G608- is installed in brake servo → Chapter
14 -  Cap
15 -  Seal
Vacuum hose for brake servo
16 -  Sealing ring
Between brake master cylinder and brake servo
17 -  Brake servo
Functional check:
–  With engine switched off, depress brake pedal firmly several times (to exhaust vacuum in unit).
–  Now step on and hold brake pedal with medium pressure and start engine. If the brake servo is functioning properly, the brake pedal will be felt to go down as the servo takes effect.
Replace completely in the event of a fault (before doing so, check brake servo vacuum system) → Chapter
Removing and installing → Chapter
18 -  Seal
Renew
Bonded (only when originally assembled at factory)
Bonded joint at brake servo and plenum chamber bulkhead does not have to be renewed

 
     
Bolting sequence:
 

Assembly overview - brake servo/brake master cylinder, LHD vehicles

Brake servo and brake master cylinder
...

Assembly overview - brake servo/brake master cylinder, RHD vehicles
  Note Only use new brake fluid conforming to VW standard (VW 501 14).     1 -  Cap ...

Other materials:

Notes for wheel alignment
Wheel alignment must be performed only using a VW/AUDI-approved wheel alignment unit! Whenever wheels are aligned, both the front and rear axles must be measured. –  Carry alignment out with the wheel alignm ...

Removing and installing net partition
Removing –  Fold down both rear seat backrests. –  Pull net partition -1- towards right out of mountings -2- on right rear seat backrest (2/3), and remove it. Installing ...

Test preparations, wheel alignment with no driver assist systems
Special tools and workshop equipment required Wheel alignment computer -V.A.G 1813F- or VW/Audi-approved wheel alignment units Brake pedal depressor -V.A.G 1869/2- Tool insert 18 mm -T10179- Shock absorber set ...

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