Volkswagen Golf Service & Repair Manual: Removing and installing brake master cylinder, RHD vehicles
 Note
| If there are problems with the brake servo, first check the
brake servo vacuum system
→ Chapter. |
| Special tools and workshop equipment
required |
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| Brake filling and bleeding equipment -VAS 5234- |
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| Torque wrench -V.A.G 1331- |
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| Fitting location of brake master cylinder in RHD vehicles: |
| 1 - |
Brake servo and brake master cylinder |
| 2 - |
ABS hydraulic unit -N55- and ABS control unit -J104- |
| – |
If vehicle has a coded radio, note radio code or, if
necessary, request it. |
| Vehicle with diesel engine: |
| – |
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.
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| – |
Release and 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-. |
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| – |
Remove securing bolts -2-. |
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| – |
Open retainer -arrow- and
unclip fuel lines -1-. |
| – |
Then lay fuel filter to one side. |
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| – |
Release electrical connector -1-
and pull off. |
| – |
Release catches using a screwdriver
-arrow-. |
| – |
Place coolant expansion tank onto engine. |
| – |
Remove upper toothed belt guard
→ Rep. gr.15. |
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| 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. |
|
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|
| – |
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. |
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| Vehicles with air conditioning: |
| – |
Evacuate refrigerant circuit
→ Heating, air conditioning; Rep. gr.00. |
| – |
Unscrew nuts -2- on refrigerant
line -1-. |
| – |
Remove refrigerant line -1-. |
| 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-. |
|
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|
| – |
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-. |
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| – |
Release connector -1- and pull
off brake light switch -F--2-. |
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| – |
Release electrical connector -2-
for brake fluid level warning contact -F34- and pull it off
brake fluid reservoir -1-. |
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| – |
Pull out spreader rivet -3- in
-direction of arrow-. |
| – |
Pull brake fluid reservoir -1-
upwards off brake master cylinder -2- |
|
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|
| – |
When doing this, gently press refrigerant line
-1- upwards. |
|
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| – |
Unscrew brake lines -1- from
brake master cylinder -3-. |
| – |
Seal brake lines with sealing plugs from repair kit Part
No. 1H0 698 311 A. |
| – |
Remove heat shield -3-. |
| – |
Carefully remove brake master cylinder from brake servo. |
| Install in reverse order of removal, observing the
following: |
| – |
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. |
| – |
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. |
| → Chapter „Assembly overview - brake servo/brake master
cylinder, RHD vehicles“ |
| → Chapter „Connecting brake lines to hydraulic unit, RHD
vehicles“ |
| Toothed belt guard
→ Rep. gr.15 |
| Air conditioning
→ Heating, air conditioning; Rep. gr.87 |
| Front bleed valves
→ Chapter „Assembly overview - front brake caliper“ |
| Rear bleed valves
→ Chapter „Assembly overview - rear brake caliper“ |
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Special tools and workshop equipment
required
Brake filling and bleeding equipment -VAS 5234-
...
Vacuum pump for brake servo, diesel
vehicles
Vacuum pump for 4-cylinder diesel engine (1.6 l, common
rail):
The vacuum p ...
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Removing and installing brake master cylinder, LHD vehicles
Vacuum system