Volkswagen Golf Service & Repair Manual: Removing and installing brake servo, LHD vehicles
| Special tools and workshop equipment
required |
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| Torque wrench -V.A.G 1331- |
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| Torque wrench -V.A.G 1410- |
| Tool inserts (11 mm) -V.A.G 1331/2- |
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| Brake filling and bleeding equipment -VAS 5234- |
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| Sealing plug repair kit -1H0 698 311 A- |
| Hot air blower, e.g. hot air blower -VAS 1978/14A- |
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| 1 - |
ABS control unit -J104- and ABS hydraulic unit -N55- |
| 3 - |
Brake system pressure accumulator -VX70- |
| – |
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. |
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| 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. |
| – |
Read and note code of brake servo control unit -J539-
→ Vehicle diagnostic tester. |
| – |
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. |
| – |
Release high-voltage cables from bracket and lay to side
→ Electrical system; Rep. gr.93. |
| – |
Remove bracket for high-voltage cables on the gearbox. |
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| – |
Release and pull off connector -1-
for brake fluid level warning contact -F34--2-
on brake fluid reservoir -3-. |
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| – |
Release connector -2- and pull
it off brake servo -1-. |
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| – |
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-. |
| Ensure no brake fluid gets onto contacts. |
| – |
Place sufficient lint-free cloths in area of engine,
subframe and gearbox. |
| 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. |
| – |
Remove dash panel trim in driver footwell
→ General body repairs, interior; Rep. gr.68. |
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| – |
Fold down floor covering -1- in
-direction of arrow-. |
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| – |
Unscrew bolt -2- and carefully
pull off brake fluid reservoir -1-
upwards. |
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| – |
Mark position of brake lines -2 to 4-
on brake master cylinder -1-. |
| – |
Unscrew brake lines -2 to 4-
from brake master cylinder -1-. |
| – |
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-. |
| – |
Unscrew brake line -2- from
brake system pressure accumulator -VX70- and remove it. |
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| – |
Unscrew nuts -3 and 4- from
brake servo. |
| – |
If brake servo gets jammed in holes, loosen both remaining
nuts -1 and 2- on the mounting
bracket. |
| – |
Carefully pull brake servo off plenum chamber bulkhead. |
| – |
Carefully remove brake servo from the vehicle. |
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| – |
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. |
| 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. |
| → 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. |
| → General body repairs, interior; Rep. gr.68 |
| → Running gear, axles, steering; Rep. gr.48. |
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Special tools and workshop equipment
required
Torque wrench -V.A.G 1331-
...
Special tools and workshop equipment
required
Torque wrench -V.A.G 1331-
...
Other materials:
Performing maintenance test
WARNING
It is not permissible to test or charge batteries
whose colour indicator is light yellow. Do not
slave/jump start the vehicle!
Danger of explosion when checking and charging ...
Checklist
To ensure your own safety and the safety of your passengers, observe
the following actions in the specified order :
Stop the vehicle at a safe distance away
from moving traffic and on a suitable surface .
Switch on the hazard warning lights using
the button .
Switch on the ...
Front airbags
Fig. 70 Location and deployment zone of
the driver front airbag
Fig. 71 Location and deployment zone of
the front passenger front airbag
First read and observe the introductory information
and safety warnings In conjunction with the seat belts, the front airbag
system gives the front o ...
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Note
Removing and installing brake system pressure accumulator -VX70-, RHD
vehicles
Removing and installing brake servo, right-hand drive vehicle