Volkswagen Workshop Service and Repair Manuals

Notes:

• ◆ The brake pedal position sender is only supplied as a repair kit. Apart from the sender, this repair kit contains a sealing ring, circlip and four different spacer caps.

• ‒ one white spacer cap
• ‒ one green spacer cap
• ‒ one blue spacer cap
• ‒ one red spacer cap

• ◆ The spacer caps are of differing length.
• ◆ When renewing the sender note the colour of spacer cap. The new sender must have the same colour cap as the old sender.
• ◆ On the brake servo housing in vicinity of the sender location there is a coloured spot, which is identical to that of the spacer cap.

Removing

• ‒ Release brake servo vacuum by operating the brake pedal several times.
• ‒ Swing coolant expansion tank to side.
• ‒ Pull connector off sender.
• ‒ → Lever out circlip with scriber or similar.

• ‒ → Pull sender out of brake servo.

Installing

Note:

Fit the circlip so that the gap faces downwards (arrow).

• ‒ → Fit new circlip.
• ‒ Fit new sealing ring to sender. (Coat sealing ring with lubricant e.g. soft soap).

Note:

• ◆ The sender unit groove (arrow) must be 180° opposed to circlip gap.

• ‒ → Insert sender into brake servo so that the circlip engages audibly in the sender groove.
• ‒ Connect sender unit connection and ensure correctly located.

Notes:

• ◆ To ensure correctly seated pull sender by hand.
• ◆ Leaks at the sender unit sealing ring, result in insufficient braking vacuum and poor engine idling.
• ◆ For ease of illustration, shows fitting the sender unit with brake fluid reservoir removed.