VW Golf manuals

Volkswagen Golf Service & Repair Manual: Removing and installing brake master cylinder, LHD vehicles

Special tools and workshop equipment required
   
Brake filling and bleeding equipment -VAS 5234-
 

Removing and installing brake master cylinder, LHD vehicles

Torque wrench -V.A.G 1331-
 

Removing and installing brake master cylinder, LHD vehicles

Sealing tool -T10249-
Removing
–  If vehicle has a coded radio, note radio code or, if necessary, request it.
–  Disconnect battery → Electrical system; Rep. gr.27
–  Remove battery → Electrical system; Rep. gr.27.
 

Removing and installing brake master cylinder, LHD vehicles

Vehicles with diesel engine:
–  Remove engine cover panel.
–  Loosen hose clip -1- and remove air intake hose and air filter housing → Rep. gr.23.
 

Removing and installing brake master cylinder, LHD vehicles

On »R« vehicles:
–  Loosen hose clips -2- and -3-.
–  Remove air intake hose -1- and air filter housing → Rep. gr.24.
 

Removing and installing brake master cylinder, LHD vehicles

Continuation for all models:
–  Remove battery tray → Electrical system; Rep. gr.27.
–  Place sufficient lint-free cloths in area of engine and gearbox.
 

Removing and installing brake master cylinder, LHD vehicles

–  Draw off as much brake fluid as possible from brake fluid reservoir using brake filling and bleeding equipment -VAS 5234-.
 

Removing and installing brake master cylinder, LHD vehicles

Vehicles with manual gearbox:
–  Pull off supply hose -1- for clutch master cylinder, seal it using sealing tool -T10249- and tie it up, or clamp off supply hose -1- for clutch master cylinder using commercially available tool, e.g. Hazet 4590, and pull it off.
 

Removing and installing brake master cylinder, LHD vehicles

Continuation for all models:
–  Disconnect connector from brake fluid level warning contact -F34--3-, from vacuum sender -G608--2- (if fitted) and from brake light switch -F--1-.
 

Removing and installing brake master cylinder, LHD vehicles

–  Unscrew Torx bolt -1- and pull brake fluid reservoir -2- out of sealing plugs.
 

Removing and installing brake master cylinder, LHD vehicles

–  Unscrew brake lines -1- from brake master cylinder, and seal brake lines with plugs from repair kit with part no. 1H0 698 311 A.
–  Unscrew nuts -2- from brake master cylinder.
–  Remove heat shield (if installed).
–  Carefully take brake master cylinder out of brake servo.
–  Unscrew brake light switch -F- from brake master cylinder.
Installing
Install in reverse order of removal, observing the following:
–  When assembling brake master cylinder with brake servo, make sure plunger rod is properly positioned in brake master cylinder.
Seals must be located in supply hose for clutch master cylinder.
–  Bleed brake system → Chapter.
Specified torques
→ Chapter „Assembly overview - brake servo/brake master cylinder, LHD vehicles“
 

Removing and installing brake master cylinder, LHD vehicles

Removing and installing brake servo for vehicles with 1.2 l and 1.4 l petrol engines
  Note If there are problems with the brake servo, first check the brake servo vacuum system → Chapter.     ...

Removing and installing brake master cylinder, RHD vehicles
  Note If there are problems with the brake servo, first check the brake servo vacuum system → Chapter. Special tools a ...

Other materials:

Displays
Fig. 178 In the instrument cluster display: examples of recognised speed limits or overtaking restrictions with accompanying additional signs First read and observe the introductory information and safety warnings  Traffic sign recognition texts Cause and solut ...

Fitting control unit to hydraulic unit
Special tools and workshop equipment required ESD workplace -VAS 6613- Torque screwdriver -V.A.G 1624-     Torx bit T25 Severe ...

Warning lamp
First read and observe the introductory information and safety warnings  Lit up Possible cause Solution Fault in the alternator. Proceed to a qualified workshop. The electrical system should be checked. Switch off all elec ...

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