volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

Vacuum pump for brake servo (vehicles with diesel engine) > < Brake servo/brake master cylinder (left-hand drive vehicle)
Assembly overview
Assembly overview
  Note
Use only new brake fluid. Observe information on brake fluid reservoir.
   
1 - Pedal cluster
2 - Self-locking hexagon nut, 25 Nm
q   Always renew after removing.
3 - Seal
q   For brake servo.
4 - Brake servo
q   On petrol engines, the required vacuum is either taken from the intake manifold or generated by a mechanical vacuum pump.
q   Some vehicles with a petrol engine and a dual clutch gearbox which are not equipped with a HBV (hydraulic brake with vacuum servo) have a vacuum pump for brakes -V192- → Chapter.
q   Diesel engines are fitted with an vacuum pump to create the required vacuum → Chapter.
q   Functional check:
–  With engine switched off, depress brake pedal firmly several times (to exhaust vacuum in unit).
–  Now step on and hold brake pedal with medium pressure and start engine. If the brake servo is functioning properly, the brake pedal will be felt to go down as the servo takes effect.
q   Replace completely in the event of a fault (before doing so, check brake servo vacuum system) → Chapter
q   Removing and installing → Chapter.
5 - Sealing ring
6 - Brake master cylinder
q   Allocation → Electronic Parts Catalogue (ETKA).
q   Cannot be repaired. If faulty, renew as a complete unit.
q   Removing and installing → Chapter.
7 - Brake light switch -F-
q   Including brake pedal switch -F47-.
q   Removing and installing → Chapter.
8 - Torx socket head bolt, 5 Nm
9 - Clip
10 - Heat shield
11 - Self-locking hexagon nut, 25 Nm
q   Always renew after removing.
12 - Brake line, 14 Nm
q   From secondary piston circuit of brake master cylinder to hydraulic unit.
13 - Brake line, 14 Nm
q   From primary piston circuit of brake master cylinder to hydraulic unit.
14 - Sealing plug
q   Moisten with brake fluid and press into brake fluid reservoir.
15 - Brake fluid reservoir
16 - Cap
17 - Vacuum hose
q   Fit in brake servo.
18 - Vacuum sender -G608-
q   Vehicles HBS
q   Removing and installing → Chapter.
  Note
On some vehicles with no HBV (hydraulic brake with vacuum servo), a brake servo pressure sensor -G294- is fitted.
q   Removing and installing brake servo pressure sensor -G294- → Chapter.
19 - Sealing plug
q   Connection for vacuum hose.

   

Vacuum pump for brake servo (vehicles with diesel engine) > < Brake servo/brake master cylinder (left-hand drive vehicle)