VW Golf manuals

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

Torque wrench -V.A.G 1331-
 

Removing and installing brake servo, LHD vehicles

Sealing tool -T10249-
Adhesive strip remover -VAS 6349-
Drill, cordless screwdriver or grinder
Removing
–  If vehicle has a coded radio, note radio code or, if necessary, request it.
–  Disconnect battery → Electrical system; Rep. gr.27
–  Remove battery → Electrical system; Rep. gr.27.
 

Removing and installing brake servo, LHD vehicles

Vehicles with diesel engine:
–  Remove engine cover panel.
–  Loosen hose clip -1- and remove air intake hose and air filter housing → Rep. gr.23.
 

Removing and installing brake servo, LHD vehicles

On »R« vehicles:
–  Loosen hose clips -2- and -3-.
–  Remove air intake hose -1- and air filter housing → Rep. gr.24.
Continuation for all models:
–  Remove battery tray → Electrical system; Rep. gr.27.
–  Place sufficient lint-free cloths in area of engine and gearbox.
 

Removing and installing brake servo, LHD vehicles

–  Draw off as much brake fluid as possible from brake fluid reservoir using brake filling and bleeding equipment -VAS 5234-.
 

Removing and installing brake servo, LHD vehicles

Vehicles with manual gearbox:
–  Pull off supply hose -1- for clutch master cylinder, seal it using sealing tool -T10249- and tie it up, or clamp off supply hose -1- for clutch master cylinder using commercially available tool, e.g. Hazet 4590, and pull it off.
 

Removing and installing brake servo, LHD vehicles

Continuation for all models:
–  Disconnect connector from brake fluid level warning contact -F34--3-, from vacuum sender -G608--2- (if fitted) and from brake light switch -F--1-.
–  Dissipate vacuum in brake servo by depressing brake pedal several times.
–  Pull vacuum hose out of brake servo.
–  Unscrew brake lines from brake master cylinder and seal brake lines with plugs from repair kit Part No. 1H0 698 311 A.
Vehicles with 7-speed dual clutch gearbox:
–  Remove selector cable and cable support bracket from gearbox → Rep. gr.34.
Continuation for all models:
–  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 centre console 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.
 

Removing and installing brake servo, LHD vehicles

–  Remove knee airbag -1- → General body repairs, interior; Rep. gr.69.
 

Removing and installing brake servo, LHD vehicles

–  Remove footwell vent on driver side → Heating, air conditioning system; Rep. gr.87.
 

Removing and installing brake servo, LHD vehicles

–  Remove control unit for data bus diagnostic interface -J533--3- and lay it to one side → Electrical system; Rep. gr.97.
 

Removing and installing brake servo, LHD vehicles

–  Unbolt -2- crash bar for brake pedal -1-, detach it, 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, LHD vehicles

–  Unscrew bolts -1- and fold footwell trim -2- in direction of arrow towards vehicle interior.
 

Removing and installing brake servo, LHD vehicles

–  Unscrew nuts -3 and 4- from brake servo.
–  Pull brake servo off plenum chamber bulkhead, applying force to separate bonded joint.
–  Carefully remove brake servo from the vehicle.
–  Unscrew nuts for brake master cylinder.
–  Remove heat shield, if fitted.
–  Carefully remove brake master cylinder from brake servo.
Installing
Install in reverse order of removal, observing the following:
  Note
The brake servo is given the additional bonded joint only during factory assembly.
The adhesive bond between the brake servo and the plenum chamber bulkhead does not need to be renewed, but the gasket does.
–  Remove all adhesive residue from plenum chamber bulkhead and, as needed, from brake servo. Use adhesive strip remover -VAS 6349- with a drill, cordless screwdriver or grinder for this purpose.
–  Operate adhesive strip remover -VAS 6349- at low speed, working against direction of rotation.
–  Renew gasket.
–  Connect brake pedal to brake servo → Chapter.
–  After installing, bleed brake system → Chapter and clutch.
Specified torques
→ Chapter
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
 

Removing and installing brake servo, LHD vehicles

Removing and installing brake light switch, RHD vehicles
Removing     Vehicle with diesel engine: –  Remove engine cover panel → ...

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.     ...

Other materials:

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Assembly overview - ignition system
1 -  Bolt The specified torque influences the function of the knock sensor. 20 Nm 2 -  Knock sensor 1 -G61- Removing and installing → Chapter 3 -  Spar ...

Switch off the lane departure warning system in the following situations
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