Volkswagen Golf Service & Repair Manual: Work instructions

Volkswagen Golf Service & Repair Manual / Brake system (hybrid) / Brakes, hydraulics, regulator, servo / Brake lines / Work instructions

Unbolt relevant brake line at brake caliper or wheel brake cylinder; catch escaping brake fluid and dispose of this as per regulations.

–	Cut through brake line at a suitable point (straight, freely accessible section) using pipe cutter -2-.

–	Remove section to be renewed.

–	Degrease brake line surface.

Work instructions

–	Clamp brake line in set of grips -4- so that approx. 50 mm project from plastic jaws.

–	Clamp scraper -3- into a drill and place it onto brake line.

–	At slow drill speed and with gentle pressure on brake line, scrape coating off brake line.

Length of scraping is determined by stop in scraper.

–	Pull scraper off brake line and remove scrapings.

Work instructions

–	Remove grip wrench and slide brake line nut -D- onto brake line.

Work instructions

–	Slide brake line -B- up to stop -A- in flanging tool.

Note

Brake line must be positioned against stop when the hexagon socket head bolts are tightened, or the flange will not be formed correctly.

–	Clamp brake line in flanging tool until brake line can no longer be moved. Fold up stop -A-, then tighten hexagon socket head bolts diagonally using angle screwdriver -C-.

Work instructions

–	Turn spindle as far as stop in flanging tool.

–	Turn spindle back again.

–	Unscrew hexagon socket head bolts in diagonal sequence.

–	Remove brake line from flanging tool, then clean and inspect brake line and flange.

Briefly flush the section of brake line remaining in the vehicle:

–	Connect brake filling and bleeding unit -VAS 5234-, connect hose of bleed bottle to brake line flange and allow brake filling and bleeding unit -VAS 5234- to run briefly until a little brake fluid has run through.

–	Blow out new brake line to be inserted with compressed air.

Work instructions

–	Join brake lines using connector -E-.

–	Install brake line.

–	Bleed brake system → Chapter.

Work instructions

Assembly overview - flanging tool

1 - Flanging tool upper part Unbolt to change flanging jaws 2 - Fastening for handle Must be unscrewed to access ...

Hydraulic system

General notes on brake fluid Only use new brake fluid conforming to VW standard (VW 501 14). Note ...

Other materials:

Removing and installing remote control receiver for auxiliary coolant heater -R149-, Golf Variant
Note If the remote control receiver for auxiliary coolant heater -R149- is renewed, the remote control receiver for auxiliary coolant heater -R149- needs to be adapted to the auxiliary and supplementary heater using the vehicle diagnostic tester ...

Running-in
First read and observe the introductory information and safety warnings Please follow the regulations concerning running-in new parts. Running in a new engine Any new engine has to be run in during the first 1,500 kilometres. During its first few hours of running, the internal friction in ...

Charging battery in refresh charge mode with battery charger -VAS 5903-
WARNING Danger of injury! Observe warning notices and safety regulations → Chapter! WARNING It is not permissible ...