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

Volkswagen Golf Service & Repair Manual / Brake system (hybrid) / Brakes, hydraulics, regulator, servo / Brake servo and brake master cylinder / 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

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:

Overview of fitting locations - entry and start authorisation system, LHD vehicles
1 - Immobiliser reader coil -D2- Removing and installing → Chapter 2 - Control unit for electronic steering column lock -J764- Removing and installing → Running gear, axles, steering ...

Checking for leaks
Note The average air pressure of the earth's atmosphere at sea level is 1013 mbar and decreases steeply as the altitude increases (approx. 100 mbar/1,000 m altitude). Local and time fluctuations also influence vacuum generation. ...

Safety precautions when working in the vicinity of high-voltage components
Risk of death due to high voltage The high voltage system carries high voltage. If high-voltage components or high-voltage lines become damaged, there is a risk of severe or fatal injury due to electric shock. – Carry out visual inspection of high ...