volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

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Installing > < Removing and installing brake servo, left-hand drive

Polo Mk5

Removing
Removing
–  Note or request radio code on vehicles with coded radio if necessary.
–  Disconnect battery. → Electrical system; Rep. gr.27.
–  Remove intake hose and air filter housing.
–  Remove engine control unit → Rep. gr.24.
–  Remove bracket for engine control unit.
   
–  Unbolt fastening tab for air filter.
–  Disconnect connector -A- from brake fluid level warning contact -F34-.
–  Separate connector -C- from brake light switch -F-.
–  Place sufficient lint-free cloths in area of engine and gearbox.
–  Draw off as much brake fluid as possible from brake fluid reservoir using brake filling and bleeding equipment -VAS 5234- or extraction unit -V.A.G 1869/4-.
Additional work on following engines and gearboxes:
3-cyl. injection engine (4-valve):
–  Remove throttle valve module -J338- → 3-cyl. injection engine (4-valve); Rep. gr.24.
4-cyl. injection engine, toothed belt drive:
–  Removing and installing → Electrical system; Rep. gr.27
4-cylinder diesel engine (1.6 l engine, common rail):
–  Loosen charge air pipe and screw-type clip to turbocharger → 4-cylinder diesel engine (1.6 l engine, common rail); Rep. gr.21.
–  Then unbolt pulsation damper from turbocharger and remove along with connecting hose.
Manual gearbox:
  N47-10056
–  Detach supply hose -B- for clutch master cylinder, lift clear and tie in place, or clamp off supply hose -B- for clutch master cylinder with a commercially available tool, e.g. Hazet 4590, and then pull off.
Dual clutch gearbox:
–  Remove gear selector cable from ball head and cable support → 7-speed dual clutch gearbox 0AM; Rep. gr.34.
–  Remove selector lever from selector shaft on gearbox → 7-speed dual clutch gearbox 0AM; Rep. gr.34.
Continuation for all models:
–  Push brake fluid reservoir pin through fastening tab and brake master cylinder.
–  Then pull brake fluid reservoir out of brake master cylinder.
  N47-10056
–  Mark and unscrew brake lines from brake master cylinder -1- and immediately seal brake lines with plugs from repair kit Part No. 1H0 698 311 A.
–  Pull vacuum hose out of brake servo.
–  Separate brake pedal from brake servo → Chapter.
  N47-10118
–  Remove hexagon nuts -arrows-.
–  Carefully remove brake servo from vehicle.
–  If brake servo sticks in holes, loosen both remaining nuts on mounting bracket.
–  Unscrew brake master cylinder from brake servo.
–  Remove heat shield (if installed).
–  Carefully take brake master cylinder out of brake servo.
  N47-10117

Installing > < Removing and installing brake servo, left-hand drive