VW Golf manuals

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

Special tools and workshop equipment required
   
Torque wrench -V.A.G 1331-
 

Removing and installing brake master cylinder, LHD vehicles

Torque wrench -V.A.G 1410-
Tool inserts (11 mm) -V.A.G 1331/2-
 

Removing and installing brake master cylinder, LHD vehicles

Brake filling and bleeding equipment -VAS 5234-
 

Removing and installing brake master cylinder, LHD vehicles

Sealing plug repair kit -1H0 698 311 A-
Removing:
–  Observe safety precautions when working in the area of high-voltage components → Chapter.
–  Observe the risk classification of the high-voltage system → Electric drive; Rep. gr.00.
 

Removing and installing brake master cylinder, LHD vehicles

Danger to life due to high voltage
The high-voltage system is under high voltage. If high-voltage components are damaged, there is a risk of severe or fatal injury due to electric shock.
–  Carry out visual inspection of high-voltage components and cables.
–  Never use cutting or forming tools, or any others with sharp edges.
–  Never use heat sources such as welding, soldering, thermal bonding or hot air.
 
 
–  Disconnect battery → Electrical system; Rep. gr.27.
–  Remove power and control electronics for electric drive -JX1- → Electrical system; Rep. gr.93.
–  Remove bracket for power and control electronics for electric drive -JX1- → Electrical system; Rep. gr.93.
–  Place sufficient lint-free cloths in area of engine, subframe and gearbox.
–  Draw off as much brake fluid as possible from brake fluid reservoir using brake filling and bleeding equipment -VAS 5234-.
   
–  Release and pull off connector -1- for brake fluid level warning contact -F34--2- on brake fluid reservoir -3-.
 

Removing and installing brake master cylinder, LHD vehicles

–  Unscrew bolt -2- and carefully pull off brake fluid reservoir -1- upwards.
 

Removing and installing brake master cylinder, LHD vehicles

–  Mark position of brake lines -2 to 4- on brake master cylinder -1-.
–  Unscrew brake lines -2 to 4- from brake master cylinder -1-.
–  Seal threaded holes immediately using sealing plugs -1H0 698 311 A-.
–  Fit dust caps from the bleeder valves onto brake line.
 

Removing and installing brake master cylinder, LHD vehicles

–  Remove bolts -arrows-.
–  Carefully take brake master cylinder -1- out of brake servo.
Installing:
Install in reverse order. Note the following points:
–  Thoroughly clean threaded hole for bolts → Item.
–  When assembling brake master cylinder with brake servo, make sure push rod is properly positioned in brake master cylinder.
–  When assembling brake master cylinder with brake servo, make sure seal → Item is seated correctly.
–  Fit sealing plugs onto brake fluid reservoir → Item.
–  Moisten sealing plugs → Item with brake fluid before pressing brake fluid reservoir into brake master cylinder.
–  Bleed brake system → Chapter.
–  Subsequently bleeding the brake system → Chapter.
–  Perform basic setting for electromechanical brake servo → Vehicle diagnostic tester.
Specified torques
→ Chapter „Assembly overview - brake servo/brake master cylinder, LHD vehicles“
→ Chapter „Assembly overview – Brake system pressure accumulator -VX70-“
→ Electrical system; Rep. gr.93
→ Electrical system; Rep. gr.27.
 

Removing and installing brake master cylinder, LHD vehicles

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Removing and installing brake master cylinder, RHD vehicles
Special tools and workshop equipment required     Torque wrench -V.A.G 1331-   ...

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