Volkswagen Golf Service & Repair Manual: Removing and installing brake master cylinder, LHD vehicles
| Special tools and workshop equipment
required |
|
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| Torque wrench -V.A.G 1331- |
|
|
|
| Torque wrench -V.A.G 1410- |
| Tool inserts (11 mm) -V.A.G 1331/2- |
|
|
|
| Brake filling and bleeding equipment -VAS 5234- |
|
|
|
| Sealing plug repair kit -1H0 698 311 A- |
| – |
Observe safety precautions when working in the area of
high-voltage components
→ Chapter. |
| – |
Observe the risk classification of the high-voltage system
→ Electric drive; Rep. gr.00. |
|
|
|
| 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 power and control electronics for electric drive
-JX1-
→ Electrical system; Rep. gr.93. |
| – |
Remove bracket for power and control electronics for
electric drive -JX1-
→ Electrical system; Rep. gr.93. |
| – |
Place sufficient lint-free cloths in area of engine,
subframe and gearbox. |
| – |
Draw off as much brake fluid as possible from brake fluid
reservoir using brake filling and bleeding equipment -VAS 5234-. |
|
|
|
| – |
Release and pull off connector -1-
for brake fluid level warning contact -F34--2-
on brake fluid reservoir -3-. |
|
|
|
| – |
Unscrew bolt -2- and carefully
pull off brake fluid reservoir -1-
upwards. |
|
|
|
| – |
Mark position of brake lines -2 to 4-
on brake master cylinder -1-. |
| – |
Unscrew brake lines -2 to 4-
from brake master cylinder -1-. |
| – |
Seal threaded holes immediately using sealing plugs -1H0 698
311 A-. |
| – |
Fit dust caps from the bleeder valves onto brake line. |
|
|
|
| – |
Carefully take brake master cylinder
-1- out of brake servo. |
| Install in reverse order. Note the following points: |
| – |
Thoroughly clean threaded hole for bolts
→ Item. |
| – |
When assembling brake master cylinder with brake servo, make
sure push rod is properly positioned in brake master cylinder. |
| – |
When assembling brake master cylinder with brake servo, make
sure seal
→ Item is seated correctly. |
| – |
Fit sealing plugs onto brake fluid reservoir
→ Item. |
| – |
Moisten sealing plugs
→ Item with brake fluid before pressing brake fluid
reservoir into brake master cylinder. |
| – |
Bleed brake system
→ Chapter. |
| – |
Subsequently bleeding the brake system
→ Chapter. |
| – |
Perform basic setting for electromechanical brake servo
→ Vehicle
diagnostic tester. |
| → Chapter „Assembly overview - brake servo/brake master
cylinder, LHD vehicles“ |
| → Chapter „Assembly overview – Brake system pressure accumulator
-VX70-“ |
| → Electrical system; Rep. gr.93 |
| → Electrical system; Rep. gr.27. |
|
|
|
1 -
Brake system pressure accumulator -VX70-
Removing and installing
→ Chapter
2 -
Brake line
To ...
Special tools and workshop equipment
required
Torque wrench -V.A.G 1331-
...
Other materials:
Removing and installing camshaft housing
Removing
–
Remove coolant pump
→ Chapter.
–
Remove air filter housing
→ Chapter.
–
Remove ignition coils
→ Chapter.
...
2-pack fine filler
Designation:
2-pack fine filler -LSP 784 002 A2-
Issued 06/2011
Product description
The 2-pack fine filler is a very fine, thixotropic polyester
filler.
...
Instructions for checking
The following instructions are intended to help you find the
causes of problems effectively and objectively in the event of
complaints about the brake servo or in the event of a so-called
»hard brake pedal«.
This check relates to the fo ...
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Assembly overview – Brake system pressure accumulator -VX70-, RHD vehicles
Removing and installing brake master cylinder, RHD vehicles