VW Golf manuals

Volkswagen Golf Service & Repair Manual: 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 servo, RHD vehicles with diesel engine

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, RHD vehicles with diesel engine

Hose clip pliers -V.A.G 1921-
 

Removing and installing brake servo, RHD vehicles with diesel engine

Torx screwdriver bit T30 -T10405-
 

Removing and installing brake servo, RHD vehicles with diesel engine

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 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 servo, RHD vehicles with diesel engine

–  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 servo, RHD vehicles with diesel engine

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

Removing and installing brake servo, RHD vehicles with diesel engine

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

Removing and installing brake servo, RHD vehicles with diesel engine

–  Release electrical connector -1- and pull off.
–  Release catches using a screwdriver -arrow-.
–  Place coolant expansion tank onto engine.
 

Removing and installing brake servo, RHD vehicles with diesel engine

–  Remove battery tray -1- → Electrical system; Rep. gr.27.
–  Remove noise insulation → General body repairs, exterior; Rep. gr.66.
–  Remove subframe with steering rack → Running gear, axles, steering; Rep. gr.40.
–  Remove front exhaust pipe → Rep. gr.26.
–  Drain coolant → Rep. gr.19.
–  Remove left coolant pipes → Rep. gr.19.
–  Remove rear coolant pipe → Rep. gr.19.
–  Remove exhaust gas recirculation cooler → Rep. gr.26.
 

Removing and installing brake servo, RHD vehicles with diesel engine

–  Remove exhaust gas temperature senders -1- and -2- → Rep. gr.26.
 

Removing and installing brake servo, RHD vehicles with diesel engine

–  Remove Lambda probe -arrow- → Rep. gr.23.
–  Remove emission control module → Rep. gr.26.
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, RHD vehicles with diesel engine

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, RHD vehicles with diesel engine

–  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 servo, RHD vehicles with diesel engine

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 servo, RHD vehicles with diesel engine

–  Remove heat shield -1- if present.
–  Also unscrew screw -3- with Torx screwdriver bit T30 -T10405-.
–  Pull heat shield -1- upwards out of retainers -arrows- on brake fluid reservoir -2-.
 

Removing and installing brake servo, RHD vehicles with diesel engine

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

Removing and installing brake servo, RHD vehicles with diesel engine

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

Removing and installing brake servo, RHD vehicles with diesel engine

–  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, RHD vehicles with diesel engine

–  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, RHD vehicles with diesel engine

–  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, RHD vehicles with diesel engine

–  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, RHD vehicles with diesel engine

–  Remove nuts -arrows- from mounting bracket.
–  Remove brake servo downwards.
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 „Removing and installing brake master cylinder, 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
Subframe → Running gear, axles, steering; Rep. gr.40
Cooling system → Rep. gr.19.
Emission control → Rep. gr.26.
Exhaust gas recirculation → Rep. gr.26
Exhaust system → Rep. gr.26
Toothed belt guard → Rep. gr.15
Exhaust gas temperature sender → Rep. gr.26
Fuel filter → Rep. gr.20
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, RHD vehicles with diesel engine

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 a ...

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.     ...

Other materials:

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Removing and installing retaining plate for manually operated anti-dazzle interior mirror, with rain and light sensor -G397- and without front camera for driver assist systems -R242-
  Note   With the repair procedure described, it is no longer necessary to renew the windscreen.   At the same time, it is also possible to reuse the old mirror base which has fa ...

Assembly overview - rear vehicle level senders, multi-link suspension, four-wheel drive
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