Volkswagen Golf Service & Repair Manual: Removing and installing brake servo, right-hand drive vehicle
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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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! |
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Observe safety precautions when working on the high-voltage
system
→ Chapter. |
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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. |
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Carry out visual inspection of high-voltage components and cables. |
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Never use cutting or forming tools, or any others with sharp edges. |
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Never use heat sources such as welding, soldering, thermal bonding
or hot air. |
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Disconnect battery
→ Electrical system; Rep. gr.27. |
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Remove brake master cylinder
→ Chapter. |
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Remove catalytic converter
→ Rep. gr.26. |
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Unclip air conditioning line in the area of the brake servo
→ Heating, air conditioning; Rep. gr.87. |
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Remove footwell cover on driver side
→ General body repairs, interior; Rep. gr.68. |
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Remove storage compartment on driver side
→ General body repairs, interior; Rep. gr.68. |
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Remove footwell vent -1- on
driver side
→ Heating, air conditioning system; Rep. gr.87. |
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Mark brake lines -A- and
-B- on brake master cylinder
-1-. |
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Unscrew brake lines -A- and
-B- from brake master cylinder. |
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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-. |
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Carefully pull brake servo off plenum chamber bulkhead. |
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Lay brake servo to side. |
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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. |
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Pull locking slide (red) -1-
towards front. |
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Press release tab -3- on
connector -4-. |
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Release latch -2- and pull
connector -4- off brake servo
-5-. |
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Remove adhesive residue -arrows-
from brake servo -2- and plenum
chamber bulkhead -1-. |
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To do so, apply gentle heat from hot air blower to the
adhesive residue and pull it off. |
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Thoroughly clean surfaces. |
Install in reverse order. Note the following points: |
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Renew seal between brake servo and plenum chamber bulkhead
→ Item. |
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Carefully insert brake servo and tighten nuts hand-tight. |
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Connect brake pedal to brake servo
→ Chapter. |
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Bleed brake system
→ Chapter. |
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Subsequently bleeding the brake system
→ Chapter. |
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Code brake servo control unit -J539-
→ Vehicle diagnostic tester. |
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Perform basic setting for electromechanical brake servo
→ Vehicle
diagnostic tester. |
→ 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. |
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Special tools and workshop equipment
required
Torque wrench -V.A.G 1331-
...
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 ...
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