Volkswagen Golf Service & Repair Manual: Assembly overview - brake servo/brake master cylinder, RHD vehicles

Volkswagen Golf Service & Repair Manual / Brake system / Brakes, hydraulics, regulator, servo / Brake servo and brake master cylinder / Assembly overview - brake servo/brake master cylinder, RHD vehicles

Note

Only use new brake fluid conforming to VW standard (VW 501 14).

Assembly overview - brake servo/brake master cylinder, RHD vehicles

1 -

Cap

2 -	Brake fluid reservoir

With brake fluid level warning contact -F34-

3 -	Brake servo

Removing and installing → Chapter

Functional check:

–	With engine switched off, depress brake pedal firmly several times (to exhaust vacuum in unit).

–	Now step on and hold brake pedal with medium pressure and start engine. If the brake servo is functioning properly, the brake pedal will be felt to go down as the servo takes effect.

Replace completely in the event of a fault (before doing so, check brake servo vacuum system) → Chapter

4 -

Seal

Vacuum hose for brake servo

5 -	Vacuum line

6 -

Seal

Always renew after removing

Bonded (only when originally assembled at factory)

Remove adhesive residue

Bonded joint at brake servo and plenum chamber bulkhead does not have to be renewed

7 -

Nut

Qty. 2

20 Nm

8 -	Mounting bracket with brake pedal

Removing mounting bracket → Chapter

Removing brake pedal → Chapter

Separating brake pedal from brake servo → Chapter

Connecting brake pedal to brake servo → Chapter

9 -

Seal

Renew if damaged

Ensure that seals are correctly seated

Between brake master cylinder and brake servo

10 -	Brake master cylinder

Removing and installing → Chapter

Connecting brake line → Chapter

When attaching brake master cylinder to brake servo, make sure plunger rod is properly positioned in brake master cylinder.

11 -	Brake light switch -F-

Removing and installing → Chapter

12 -

Bolt

8 Nm

13 -

Bolt

8 Nm

14 -	Heat shield

On brake fluid reservoir

15 -	Heat shield

For brake servo

16 -

Nut

Always renew after removing

Qty. 2

Self-locking

23 Nm

17 -	Brake line

From secondary piston circuit of brake master cylinder to hydraulic unit.

Repairing brake lines → Chapter

14 Nm

18 -	Sealing plug

Renew if damaged

Ensure that seals are correctly seated

Moisten sealing plugs with brake fluid before pressing brake fluid reservoir into brake master cylinder

Between brake master cylinder and brake fluid reservoir

19 -	Brake line

From primary piston circuit of brake master cylinder to hydraulic unit.

Repairing brake lines → Chapter

14 Nm

20 -	Spreader rivet

For securing brake fluid reservoir

Assembly overview - brake servo/brake master cylinder, LHD vehicles

Note Only use new brake fluid conforming to VW standard (VW 501 14). 1 - Self-locking ...

Removing and installing brake light switch, LHD vehicles

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Other materials:

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Routing and securing lines
Risk of damage to lines Lines may become damaged by moving or hot components. – Route lines in their original positions. – Ensure that there is sufficient clearance to moving or hot components. ...

Current draw test
WARNING It is not permissible to test or charge batteries whose magic eye shows light yellow. Do not slave/jump start the vehicle! Danger of explosion when checking and charging or ...