VW Golf manuals

Volkswagen Golf Service & Repair Manual: 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 and workshop equipment required
   
Brake filling and bleeding equipment -VAS 5234-
 

Removing and installing brake master cylinder, RHD vehicles

Torque wrench -V.A.G 1331-
 

Removing and installing brake master cylinder, RHD vehicles

Sealing tool -T10249-
 

Removing and installing brake master cylinder, RHD vehicles

Fitting location of brake master cylinder in RHD vehicles:
1 -  Brake servo and brake master cylinder
2 -  ABS hydraulic unit -N55- and ABS control unit -J104-
Removing
–  If vehicle has a coded radio, note radio code or, if necessary, request it.
Vehicle with diesel engine:
–  Remove engine cover panel → Rep. gr.10.
The fuel system is pressurised.Risk of injury due to fuel which may spurt out.Wear eye pretection.Wear protective gloves.Release pressure: place clean cloth around connection, and carefully open connection.
 

Removing and installing brake master cylinder, RHD vehicles

–  Release and pull off fuel supply lines -1- and -2-.
–  Separate plug-in connectors → Rep. gr.20.
–  Unclip fuel lines -1- and -2- from retainer -arrow- on coolant reservoir -3-.
 

Removing and installing brake master cylinder, RHD vehicles

–  Remove securing bolts -2-.
–  Unscrew nut -1-.
 

Removing and installing brake master cylinder, RHD vehicles

–  Open retainer -arrow- and unclip fuel lines -1-.
–  Then lay fuel filter to one side.
 

Removing and installing brake master cylinder, RHD vehicles

–  Release electrical connector -1- and pull off.
–  Release catches using a screwdriver -arrow-.
–  Place coolant expansion tank onto engine.
–  Remove upper toothed belt guard → Rep. gr.15.
 

Removing and installing brake master cylinder, RHD vehicles

Vehicles with manual gearbox:
–  If present, remove heat shield.
–  To do so, remove clamping washer -4- from plenum chamber bulkhead.
–  Open snaps -1- to -3- on heat shield.
 

Removing and installing brake master cylinder, RHD vehicles

–  Pull return hose -2- for clutch sender cylinder -3- off brake fluid reservoir -4-.
–  Seal return hose -2- for clutch master cylinder -3- with sealing tool -T10249--1- or hose clips to 25 mm -3094-.
–  Raise and tie return hose -2- in place.
 

Removing and installing brake master cylinder, RHD vehicles

Vehicles with air conditioning:
–  Evacuate refrigerant circuit → Heating, air conditioning; Rep. gr.00.
–  Unscrew nuts -2- on refrigerant line -1-.
–  Remove refrigerant line -1-.
Continuation for all models:
  Note
The illustration shows installation position of ABS hydraulic unit -N55- and ABS control unit -J104- on a LHD vehicle.
–  Place sufficient lint-free cloths in area of engine.
–  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, RHD vehicles

–  Remove heat shield -1- if present.
–  To do this, unscrew bolt -3-.
–  Pull heat shield -1- upwards out of retainers -arrows- on brake fluid reservoir -2-.
 

Removing and installing brake master cylinder, RHD vehicles

–  Release connector -1- and pull off brake light switch -F--2-.
 

Removing and installing brake master cylinder, RHD vehicles

–  Release electrical connector -2- for brake fluid level warning contact -F34- and pull it off brake fluid reservoir -1-.
 

Removing and installing brake master cylinder, RHD vehicles

–  Pull out spreader rivet -3- in -direction of arrow-.
–  Pull brake fluid reservoir -1- upwards off brake master cylinder -2-
 

Removing and installing brake master cylinder, RHD vehicles

–  When doing this, gently press refrigerant line -1- upwards.
 

Removing and installing brake master cylinder, RHD vehicles

–  Unscrew brake lines -1- from brake master cylinder -3-.
–  Seal brake lines with sealing plugs from repair kit Part No. 1H0 698 311 A.
–  Remove nuts -arrows-.
–  Remove heat shield -3-.
–  Carefully remove brake master cylinder from brake servo.
Installing
Install in reverse order of removal, observing the following:
–  When assembling brake master cylinder with brake servo, make sure push rod is properly positioned in brake master cylinder.
–  When joining brake master cylinder to brake servo, make sure seal → Item is properly seated.
–  Ensure that seals → Item are correctly seated in brake master cylinder.
–  Moisten sealing plugs → Item with brake fluid before pressing brake fluid reservoir into brake master cylinder.
–  Bleed brake system → Chapter.
Vehicles with manual gearbox:
–  Bleed clutch mechanism → Rep. gr.30.
Vehicles with air conditioning:
–  Charge refrigerant circuit → Heating, air conditioning; Rep. gr.00.
Specified torques
→ Chapter „Assembly overview - brake servo/brake master cylinder, RHD vehicles“
→ Chapter „Connecting brake lines to hydraulic unit, RHD vehicles“
Toothed belt guard → Rep. gr.15
Fuel filter → Rep. gr.20
Air conditioning → Heating, air conditioning; Rep. gr.87
Front bleed valves → Chapter „Assembly overview - front brake caliper“
Rear bleed valves → Chapter „Assembly overview - rear brake caliper“
 

Removing and installing brake master cylinder, RHD vehicles

Removing and installing brake master cylinder, LHD vehicles
Special tools and workshop equipment required     Brake filling and bleeding equipment -VAS 5234- ...

Vacuum system
Vacuum pump for brake servo, diesel vehicles Vacuum pump for 4-cylinder diesel engine (1.6 l, common rail): The vacuum p ...

Other materials:

Using the selection menu in the instrument cluster
Fig. 16 Vehicles without a multifunction steering wheel: button ① on the windscreen wiper lever for confirming menu points, and rocker switch ② for changing menus and information displays Fig. 17 Right-hand side of the multifunction steering wheel: controls for using the menus and inform ...

Mounting tyre, wheels without and with tyre pressure monitoring
Only trained personnel may perform any assembly work on run-flat tyres. If fitted, check tyre pressure sensor using vehicle diagnostic tester, and renew it as necessary. –  Ensure proper assembly ...

Bleeding coolant circuit of auxiliary heater
The removal and installation procedures for the auxiliary heater and the circulation pump -V55- described in this Workshop Manual ensure that only a small quantity of air enters or remains in the coolant circuit. Therefore it is not necessary to bleed th ...

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