Volkswagen Golf Service & Repair Manual: 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. |
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| Special tools and workshop equipment required |
| Torque wrench -V.A.G 1331- |
| Brake filling and bleeding equipment -VAS 5234- |
| Hose clamps, up to 25 mm -3094- |
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| Hose clip pliers -V.A.G 1921- |
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| 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- |
| – |
If vehicle has a coded radio, note radio code or, if
necessary, request it. |
| – |
Remove noise insulation
→ General body repairs, exterior; Rep. gr.66. |
| – |
Drain coolant
→ Rep. gr.19. |
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| – |
Remove catalytic converter -10-
→ Rep. gr.26. |
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| – |
Loosen hose clip -2- and remove
coolant hose. |
| – |
Remove bolts -arrows- and
swivel coolant lines -1- to right. |
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| – |
Remove heat shield -1-. |
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| – |
Detach hoses from retainer -3-. |
| – |
Loosen clips -arrows- and
remove upper toothed belt guard -1-. |
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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. |
| 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. |
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| Continuation for all models: |
| – |
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-. |
Note
| The illustration shows installation position of ABS
hydraulic unit -N55- and ABS control unit -J104- on a LHD
vehicle. |
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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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| – |
Dissipate vacuum in brake servo by depressing brake pedal
several times. |
| – |
Pull vacuum line -4- out of
brake servo -1-. |
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| – |
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 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. |
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| – |
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. |
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| – |
Remove nuts -arrows- from
mounting bracket. |
| 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. |
| → Chapter „Assembly overview - brake servo/brake master
cylinder, RHD vehicles“ |
| → Chapter „Connecting brake lines to hydraulic unit, 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 |
| Catalytic converter
→ Rep. gr.26 |
| Coolant lines on turbocharger
→ Rep. gr.21. |
| Toothed belt guard
→ Rep. gr.15 |
| 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“ |
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Note
If there are problems with the brake servo, first check the
brake servo vacuum system
→ Chapter.
...
Special tools and workshop equipment
required
Brake filling and bleeding equipment -VAS 5234-
...
Other materials:
Adjusting camber on rear axle, multi-link suspension
Special tools and workshop equipment
required
Torque wrench -V.A.G 1332-
Tool insert 18 mm -T10179-
...
Summary of Cruise Indicators
Traffic-Aware Cruise Control is
available
but is not actively controlling your speed
until you activate it. The number shown in
gray is the cruising speed that will be set
when you engage Traffic-Aware Cruise
Control.
Traffic-Aware Cruise Control is
actively
cruising and is either maintain ...
Tools and materials commercially available
Caution
Non-authorised tools or materials (e.g. leak
inhibitor additive) may cause damage or adversely
influence the system.
Only tools and materials a ...
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