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:

Removing and installing knock sensor 1 -G61
Removing –  Remove air conditioner compressor from bracket and tie up → Heating, air conditioning; Rep. gr.87.     –  Disconnect electrical connector ...

Cigarette lighter -U1-
The following descriptions apply to the rear left cigarette lighter -U3-, rear right cigarette lighter -U7-, rear cigarette lighter -U9-, 12 V socket 2 -U18-, 12 V socket 3 -U19-, 12 V socket 4 -U20-, cigarette lighter 2 -U25- and 12 V socket 5 -U26- so ...

Removing and installing heat shield for centre exhaust system
  Note The removal and installation procedures may have to be modified slightly depending on engine fitted. Removing –  Removing rear exhaust system → Rep. gr.26. –  Loosen lock washers -2-. ...

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