Volkswagen Golf Service & Repair Manual: Removing and installing brake servo, LHD 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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| Adhesive strip remover -VAS 6349- |
| Drill, cordless screwdriver or grinder |
| – |
If vehicle has a coded radio, note radio code or, if
necessary, request it. |
| – |
Disconnect battery
→ Electrical system; Rep. gr.27 |
| – |
Remove battery
→ Electrical system; Rep. gr.27. |
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| Vehicles with diesel engine: |
| – |
Remove engine cover panel. |
| – |
Loosen hose clip -1- and remove
air intake hose and air filter housing
→ Rep. gr.23. |
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| – |
Loosen hose clips -2- and
-3-. |
| – |
Remove air intake hose -1- and
air filter housing
→ Rep. gr.24. |
| Continuation for all models: |
| – |
Remove battery tray
→ Electrical system; Rep. gr.27. |
| – |
Place sufficient lint-free cloths in area of engine and
gearbox. |
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| – |
Draw off as much brake fluid as possible from brake fluid
reservoir using brake filling and bleeding equipment -VAS 5234-. |
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| Vehicles with manual gearbox: |
| – |
Pull off supply hose -1- for
clutch master cylinder, seal it using sealing tool -T10249- and
tie it up, or clamp off supply hose -1-
for clutch master cylinder using commercially available tool,
e.g. Hazet 4590, and pull it off. |
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| Continuation for all models: |
| – |
Disconnect connector from brake fluid level warning contact
-F34--3-, from vacuum sender -G608--2-
(if fitted) and from brake light switch -F--1-. |
| – |
Dissipate vacuum in brake servo by depressing brake pedal
several times. |
| – |
Pull vacuum hose out of brake servo. |
| – |
Unscrew brake lines from brake master cylinder and seal
brake lines with plugs from repair kit Part No. 1H0 698 311 A. |
| Vehicles with 7-speed dual clutch gearbox: |
| – |
Remove selector cable and cable support bracket from gearbox
→ Rep. gr.34. |
| Continuation for all models: |
| – |
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 centre console 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. |
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| – |
Remove knee airbag -1-
→ General body repairs, interior; Rep. gr.69. |
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| – |
Remove footwell vent on driver side
→ Heating, air conditioning system; Rep. gr.87. |
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| – |
Remove control unit for data bus diagnostic interface -J533--3-
and lay it to one side
→ Electrical system; Rep. gr.97. |
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| – |
Unbolt -2- crash bar for brake
pedal -1-, detach it, and lay it to
one side
→ General body repairs, interior; Rep. gr.70. |
| – |
Separate brake pedal from brake servo
→ Chapter. |
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| – |
Unscrew bolts -1- and fold
footwell trim -2- in direction of
arrow towards vehicle interior. |
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| – |
Unscrew nuts -3 and 4- from
brake servo. |
| – |
Pull brake servo off plenum chamber bulkhead, applying force
to separate bonded joint. |
| – |
Carefully remove brake servo from the vehicle. |
| – |
Unscrew nuts for brake master cylinder. |
| – |
Remove heat shield, if fitted. |
| – |
Carefully remove brake master cylinder from brake servo. |
| Install in reverse order of removal, observing the
following: |
Note
| The brake servo is given the additional bonded joint only
during factory assembly. |
| The adhesive bond between the brake servo and the plenum
chamber bulkhead does not need to be renewed, but the gasket
does. |
| – |
Remove all adhesive residue from plenum chamber bulkhead
and, as needed, from brake servo. Use adhesive strip remover
-VAS 6349- with a drill, cordless screwdriver or grinder for
this purpose. |
| – |
Operate adhesive strip remover -VAS 6349- at low speed,
working against direction of rotation. |
| – |
Connect brake pedal to brake servo
→ Chapter. |
| – |
After installing, bleed brake system
→ Chapter and clutch. |
| 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 |
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Removing
Vehicle with diesel engine:
–
Remove engine cover panel
→ ...
Note
If there are problems with the brake servo, first check the
brake servo vacuum system
→ Chapter.
...
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