VW Golf manuals

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

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

Removing and installing brake master cylinder, RHD vehicles

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

Removing and installing brake master cylinder, RHD vehicles

Brake filling and bleeding equipment -VAS 5234-
 

Removing and installing brake master cylinder, RHD vehicles

Sealing plug repair kit -1H0 698 311 A-
Hot air blower, e.g. hot air blower -VAS 1978/14A-
 

Removing and installing brake master cylinder, RHD vehicles

Location:
The brake master cylinder is located on right-hand side of the engine compartment.
1 -  Brake servo and brake master cylinder
2 -  Brake system pressure accumulator -VX70-
3 -  ABS control unit -J104- with ABS hydraulic unit -N55-
Make sure not to bend the brake lines in the area of the brake master cylinder.
–  Observe safety precautions when working on the high-voltage system → Chapter.
–  Observe the risk classification of the high-voltage system → Electric drive; Rep. gr.00.
–  Disconnect battery → Electrical system; Rep. gr.27.
–  Remove engine cover → Rep. gr.10.
 

Removing and installing brake master cylinder, RHD vehicles

–  Disconnect fuel lines -1- and -2- and lay to side. Separate plug-in connectors → Rep. gr.20.
 

Removing and installing brake master cylinder, RHD vehicles

Vehicle with heat shield:
–  Remove bolt -1-.
–  Detach heat shield -2- at top of brake fluid reservoir -3--arrows-.
Continuation for all models:
–  Place sufficient lint-free cloths in area of engine, subframe and gearbox.
 

Removing and installing brake master cylinder, RHD vehicles

–  Release and disconnect connector -2- from brake fluid level warning contact -F34- at brake fluid reservoir -1-.
–  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

–  Mark brake lines -A- and -B- on brake master cylinder.
–  Unscrew brake lines -A- and -B- from brake master cylinder.
–  Immediately seal brake lines and open connections with sealing plugs from repair kit -1H0 698 311 A- or suitable plugs from engine bung set -VAS 6122-.
 

Removing and installing brake master cylinder, RHD vehicles

–  Remove bolts -arrows-.
–  Remove brake master cylinder -1- from brake servo.
Installing:
Install in reverse order. Note the following points:
–  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 is properly seated.
–  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 system pressure accumulator -VX70-, RHD vehicles“
→ Heating, air conditioning system; Rep. gr.87.
→ Rep. gr.87
→ Rep. gr.93
→ Rep. gr.93
 

Removing and installing brake master cylinder, RHD vehicles

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

Removing and installing brake system pressure accumulator -VX70-, LHD vehicles
Special tools and workshop equipment required     Torque wrench -V.A.G 1331-   ...

Other materials:

Removing and installing ESP sensor unit -G419-
The lateral acceleration sender -G200-, the yaw rate sender -G202- and the longitudinal acceleration sender -G251- are installed together with the control unit for electromechanical parking brake -J540- in the ABS control unit -J104-. Th ...

Various securing systems
Fig. 77 On the rear seats: figures Ⓐ and Ⓑ illustrate the main securing points for the child restraint system on the lower retaining rings and top tether. Figure Ⓒ shows how to secure the child restraint system using the vehicle seat belt First read and observe the introductory informa ...

Electrical components
some point, you have probably received an electric shock when touching a metal object. This is due to the electrostatic charge accumulated by the human body. This charge can cause malfunctions if you touch the electric steering rack and steering column c ...

© 2016-2020 Copyright www.vwgolf.org