VW Golf manuals

Volkswagen Golf Service & Repair Manual: Removing and installing brake servo for vehicles with 1.2 l and 1.4 l petrol engines

Volkswagen Golf Service & Repair Manual / Brake system / Brakes, hydraulics, regulator, servo / Brake servo and brake master cylinder / 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 servo for vehicles with 1.2 l and 1.4 l petrol engines

Special tools and workshop equipment required
Release tool -T10159 A-
Sealing tool -T10249-
Torque wrench -V.A.G 1331-
Brake filling and bleeding equipment -VAS 5234-

 
 
   
Hose clamps, up to 25 mm -3094-
 

Removing and installing brake servo for vehicles with 1.2 l and 1.4 l petrol engines

Hose clip pliers -V.A.G 1921-
 

Removing and installing brake servo for vehicles with 1.2 l and 1.4 l petrol engines

Fitting location of brake servo 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.
–  Remove noise insulation → General body repairs, exterior; Rep. gr.66.
–  Drain coolant → Rep. gr.19.
 

Removing and installing brake servo for vehicles with 1.2 l and 1.4 l petrol engines

–  Remove catalytic converter -10- → Rep. gr.26.
–  Remove bracket -7-.
 

Removing and installing brake servo for vehicles with 1.2 l and 1.4 l petrol engines

–  Loosen hose clip -2- and remove coolant hose.
–  Remove bolts -arrows- and swivel coolant lines -1- to right.
 

Removing and installing brake servo for vehicles with 1.2 l and 1.4 l petrol engines

–  Remove bolts -arrows-.
–  Remove heat shield -1-.
 

Removing and installing brake servo for vehicles with 1.2 l and 1.4 l petrol engines

–  Remove bolt -2-.
–  Detach hoses from retainer -3-.
–  Loosen clips -arrows- and remove upper toothed belt guard -1-.
 

Removing and installing brake servo for vehicles with 1.2 l and 1.4 l petrol engines

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 servo for vehicles with 1.2 l and 1.4 l petrol engines

–  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.
Vehicles with air conditioning:
–  Evacuate refrigerant circuit → Heating, air conditioning; Rep. gr.00.
–  Remove refrigerant lines with internal heat exchanger → Heating, air conditioning; Rep. gr.87.
 

Removing and installing brake servo for vehicles with 1.2 l and 1.4 l petrol engines

Continuation for all models:
–  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-.
  Note
The illustration shows installation position of ABS hydraulic unit -N55- and ABS control unit -J104- on a LHD vehicle.
 

Removing and installing brake servo for vehicles with 1.2 l and 1.4 l petrol engines

–  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 servo for vehicles with 1.2 l and 1.4 l petrol engines

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

Removing and installing brake servo for vehicles with 1.2 l and 1.4 l petrol engines

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

Removing and installing brake servo for vehicles with 1.2 l and 1.4 l petrol engines

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

Removing and installing brake servo for vehicles with 1.2 l and 1.4 l petrol engines

–  Dissipate vacuum in brake servo by depressing brake pedal several times.
–  Pull vacuum line -4- out of brake servo -1-.
 

Removing and installing brake servo for vehicles with 1.2 l and 1.4 l petrol engines

–  Unbolt brake lines -2- from brake master cylinder -1-.
–  Detach brake lines from brake master cylinder and seal brake lines with 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.
–  Remove dash panel end cover on driver side → General body repairs, interior; Rep. gr.70.
–  Remove footwell cover on driver side → General body repairs, interior; Rep. gr.68
–  Remove storage compartment on driver side → General body repairs, interior; Rep. gr.68
–  Remove dash panel cover on driver side → General body repairs, interior; Rep. gr.68.
–  Remove knee airbag → General body repairs, interior; Rep. gr.69.
 

Removing and installing brake servo for vehicles with 1.2 l and 1.4 l petrol engines

–  Remove footwell vent -1- on driver side → Heating, air conditioning system; Rep. gr.87.
–  To do this, unscrew bolt -2- and remove footwell vent on driver side -1-.
–  Unbolt crash bar for brake pedal and lay it to one side → General body repairs, interior; Rep. gr.70.
–  Separate brake pedal from brake servo → Chapter.
 

Removing and installing brake servo for vehicles with 1.2 l and 1.4 l petrol engines

–  Remove nuts -arrows- from mounting bracket.
Installing
Install in reverse order of removal, observing the following:
  Note
The brake servo only has the additional bonded joint at the seal when originally assembled at the factory.
The adhesive bond between the plenum chamber bulkhead and the brake servo does not have to be renewed.
–  Remove all adhesive residues from the plenum chamber bulkhead and (if applicable) from the brake servo. Use adhesive strip remover -VAS 6349- and a drill, cordless screwdriver or grinder for this purpose.
–  Operate adhesive strip remover -VAS 6349- at low speed, working against direction of rotation.
–  Carefully insert brake servo and tighten nuts.
–  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.
–  Connect brake pedal to brake servo → Chapter.
–  Fill coolant → Rep. gr.19.
–  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“
Crash bar → General body repairs, interior; Rep. gr.70.
Footwell vents → Heating, air conditioning system; Rep. gr.87.
Knee airbag → General body repairs, interior; Rep. gr.69.
Covers on driver side → General body repairs, interior; Rep. gr.68
Catalytic converter → Rep. gr.26
Coolant lines on turbocharger → Rep. gr.21.
Toothed belt guard → Rep. gr.15
Air conditioning → Heating, air conditioning; Rep. gr.87
Battery → Electrical system; Rep. gr.27
Noise insulation → General body repairs, exterior; Rep. gr.66.
Front bleed valves → Chapter „Assembly overview - front brake caliper“
Rear bleed valves → Chapter „Assembly overview - rear brake caliper“
 

Removing and installing brake servo for vehicles with 1.2 l and 1.4 l petrol engines

Removing and installing brake servo, RHD vehicles with diesel engine
  Note If there are problems with the brake servo, first check the brake servo vacuum system → Chapter.     ...

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

Other materials:

Refrigerant circuit components
  Caution Non-authorised tools or materials (e.g. leak inhibitor additive) may cause damage or adversely influence the system. Only tools and materials approved by the manufac ...

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 ...

Changing gear using Tiptronic
Fig. 138 Selector lever in Tiptronic position (left-hand drive). The controls are mirrored for right-hand drive vehicles Fig. 139 Steering wheel with two paddles for Tiptronic First read and observe the introductory information and safety warnings Using Tiptronic, the gears can be shifte ...

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