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:

Wheel bolts, versions
Explanations regarding types of convex seats There are two different versions of convex tapered seats, the spherical seat and the tapered.     The spherical seat is the curved surface of a s ...

Checking pressures in refrigerant circuit (using air conditioner service station)
  Note Check the cooling performance. The air conditioning system is operating correctly if the air emerging from the vent on the dashboard is at a temperature of 7oC or less. Set the Climatronic to: “LO”. ...

Removing and installing ignition key withdrawal lock solenoid -N376-
Removing –  Remove lower steering column trim → General body repairs, interior; Rep. gr.68.     –  Release retaining clip -arrow A-, and pull ...

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