VW Golf manuals

Volkswagen Golf Service & Repair Manual: Removing and installing brake servo, right-hand drive vehicle

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

Removing and installing brake servo, right-hand drive vehicle

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

Removing and installing brake servo, right-hand drive vehicle

Brake filling and bleeding equipment -VAS 5234-
 

Removing and installing brake servo, right-hand drive vehicle

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

Removing and installing brake servo, right-hand drive vehicle

Location:
The brake servo with brake master cylinder is located on the 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-
Do not bend the brake lines in the area of the hydraulic unit!
–  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.
 

Removing and installing brake servo, right-hand drive vehicle

Danger to life due to high voltage
The high-voltage system is under high voltage. If high-voltage components are damaged, there is a risk of severe or fatal injury due to electric shock.
–  Carry out visual inspection of high-voltage components and cables.
–  Never use cutting or forming tools, or any others with sharp edges.
–  Never use heat sources such as welding, soldering, thermal bonding or hot air.
 
 
–  Disconnect battery → Electrical system; Rep. gr.27.
–  Remove brake master cylinder → Chapter.
–  Remove catalytic converter → Rep. gr.26.
–  Unclip air conditioning line in the area of the brake servo → Heating, air conditioning; Rep. gr.87.
–  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 footwell vent -1- on driver side → Heating, air conditioning system; Rep. gr.87.
   
–  Loosen nuts -arrows- on mounting bracket as far as possible.
Brake lines must not be disconnected yet.
  Note
A second mechanic is required for further removal.
–  Depress brake pedal firmly and hold.
–  Have the second mechanic grasp the brake servo and pull it towards front.
  Note
By doing so, the bonded joint between the brake servo and the plenum chamber bulkhead will be separated.
Ensure that the brake lines are not bent.
If the bonded joint cannot be separated, the nuts must be unscrewed.
Risk of damage to the plenum chamber bulkhead due to improper separation of the bonded joint.
Never lever the brake servo off the plenum chamber bulkhead to separate the bonded joint.
–  Separate brake pedal from brake servo → Chapter.
–  Draw off as much brake fluid as possible from brake fluid reservoir using brake filling and bleeding equipment -VAS 5234-.
 

Removing and installing brake servo, right-hand drive vehicle

–  Mark brake lines -A- and -B- on brake master cylinder -1-.
–  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-.
–  Carefully pull brake servo off plenum chamber bulkhead.
–  Lay brake servo to side.
 

Removing and installing brake servo, right-hand drive vehicle

–  Release connector -2- and pull it off brake servo -1-.
Ensure no brake fluid gets onto contacts.
Never allow brake fluid to come into contact with fluids that contain mineral oils (e.g. oil, petrol, cleaning agents). Mineral oils damage the plugs and seals in the brake system.
Brake fluid is poisonous and must never be sucked out by mouth through a hose. Because of its caustic properties, it must also not come into contact with paintwork.
Do not reuse drawn-off brake fluid.
Always observe the relevant environmental regulations for disposal.
 

Removing and installing brake servo, right-hand drive vehicle

–  Pull locking slide (red) -1- towards front.
–  Press release tab -3- on connector -4-.
–  Release latch -2- and pull connector -4- off brake servo -5-.
 

Removing and installing brake servo, right-hand drive vehicle

–  Remove adhesive residue -arrows- from brake servo -2- and plenum chamber bulkhead -1-.
–  To do so, apply gentle heat from hot air blower to the adhesive residue and pull it off.
–  Thoroughly clean surfaces.
Installing:
Install in reverse order. Note the following points:
–  Renew seal between brake servo and plenum chamber bulkhead → Item.
–  Carefully insert brake servo and tighten nuts hand-tight.
–  Connect brake pedal to brake servo → Chapter.
–  Bleed brake system → Chapter.
–  Subsequently bleeding the brake system → Chapter.
–  Code brake servo control unit -J539- → Vehicle diagnostic tester.
–  Perform basic setting for electromechanical brake servo → Vehicle diagnostic tester.
Specified torques
→ Chapter „Assembly overview – Brake system pressure accumulator -VX70-, RHD vehicles“
→ Electrical system; Rep. gr.27.
→ Electrical system; Rep. gr.27
→ General body repairs, interior; Rep. gr.68
→ Heating, air conditioning system; Rep. gr.87.
→ Rep. gr.87
→ Rep. gr.93
→ Rep. gr.93
 

Removing and installing brake servo, right-hand drive vehicle

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

Brake lines
Repairing brake lines The flanging tool for brake lines -VAS 6056- can be used to flange brake lines with an outer pipe diameter of 5 mm without ...

Other materials:

Battery
Battery - general notes   Note All instructions and notes regarding this chapter are available under → Electrical System, General Information; Rep. gr.27.     ...

2-pack HS hardener
Designation: 2-pack HS hardener -LHA 009 041 A3- 2-pack HS hardener, fast-drying -LHA 021 004 A3- 2-pack HS hardener, extra fast-drying -LHA 009 046 A2- 2-pack HS ...

Electrical controls on the front seats
Fig. 44 Moving the front left seat forwards and backwards, adjusting the backrest and the seat cushion for height and tilt Fig. 45 Adjusting the lumbar support. First read and observe the introductory information and safety warnings The layout of the controls on the front right-hand seat ...

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