VW Golf manuals

Volkswagen Golf Service & Repair Manual: Removing and installing brake master cylinder, RHD vehicles

Special tools and workshop equipment required
   
Torque wrench -V.A.G 1331-
 

Removing and installing brake master cylinder, RHD vehicles

Torque wrench -V.A.G 1410-
Tool inserts (11 mm) -V.A.G 1331/2-
 

Removing and installing brake master cylinder, RHD vehicles

Brake filling and bleeding equipment -VAS 5234-
 

Removing and installing brake master cylinder, RHD vehicles

Sealing plug repair kit -1H0 698 311 A-
Hot air blower, e.g. hot air blower -VAS 1978/14A-
 

Removing and installing brake master cylinder, RHD vehicles

Location:
The brake master cylinder is located on right-hand side of the engine compartment.
1 -  Brake servo and brake master cylinder
2 -  Brake system pressure accumulator -VX70-
3 -  ABS control unit -J104- with ABS hydraulic unit -N55-
Make sure not to bend the brake lines in the area of the brake master cylinder.
–  Observe safety precautions when working on the high-voltage system → Chapter.
–  Observe the risk classification of the high-voltage system → Electric drive; Rep. gr.00.
–  Disconnect battery → Electrical system; Rep. gr.27.
–  Remove engine cover → Rep. gr.10.
 

Removing and installing brake master cylinder, RHD vehicles

–  Disconnect fuel lines -1- and -2- and lay to side. Separate plug-in connectors → Rep. gr.20.
 

Removing and installing brake master cylinder, RHD vehicles

Vehicle with heat shield:
–  Remove bolt -1-.
–  Detach heat shield -2- at top of brake fluid reservoir -3--arrows-.
Continuation for all models:
–  Place sufficient lint-free cloths in area of engine, subframe and gearbox.
 

Removing and installing brake master cylinder, RHD vehicles

–  Release and disconnect connector -2- from brake fluid level warning contact -F34- at brake fluid reservoir -1-.
–  Draw off as much brake fluid as possible from brake fluid reservoir using brake filling and bleeding equipment -VAS 5234-.
 

Removing and installing brake master cylinder, RHD vehicles

–  Mark brake lines -A- and -B- on brake master cylinder.
–  Unscrew brake lines -A- and -B- from brake master cylinder.
–  Immediately seal brake lines and open connections with sealing plugs from repair kit -1H0 698 311 A- or suitable plugs from engine bung set -VAS 6122-.
 

Removing and installing brake master cylinder, RHD vehicles

–  Remove bolts -arrows-.
–  Remove brake master cylinder -1- from brake servo.
Installing:
Install in reverse order. Note the following points:
–  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 is properly seated.
–  Bleed brake system → Chapter.
–  Subsequently bleeding the brake system → Chapter.
–  Perform basic setting for electromechanical brake servo → Vehicle diagnostic tester.
Specified torques
→ Chapter „Assembly overview – Brake system pressure accumulator -VX70-, RHD vehicles“
→ Heating, air conditioning system; Rep. gr.87.
→ Rep. gr.87
→ Rep. gr.93
→ Rep. gr.93
 

Removing and installing brake master cylinder, RHD vehicles

Removing and installing brake master cylinder, LHD vehicles
Special tools and workshop equipment required     Torque wrench -V.A.G 1331-   ...

Removing and installing brake system pressure accumulator -VX70-, LHD vehicles
Special tools and workshop equipment required     Torque wrench -V.A.G 1331-   ...

Other materials:

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