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Brake line > < Removing and installing brake servo unit - Vehicles with left-hand drive

Octavia Mk2

Removing and installing brake servo unit - Vehicles with right-hand drive
Removing and installing brake servo unit - Vehicles with right-hand drive
Special tools and workshop equipment required
t  Brake filling and bleeding device, e. g. -VAS 5234-
t  Plug set for engine -VAS 6122/40-
t  Supporting device -T30099-
t  Surface -T30099/1-
t  Hook -MP9–200/3-
Removing:
–  Removing driver side trim panel → Body Work; Rep. gr.70.
Vehicles up to 11.05
   
–  Unplug connector -1- from the brake light switch (if present).
–  Remove brake light switch -2- (if present) by turning 45° to the left.
Continued for all vehicles:
–  Separating the brake pedal from the brake servo unit → Chapter.
  S47-0093
–  Remove bulkhead plenum chamber → Body; Rep. gr.66.
–  Remove vacuum hose from the brake servo unit.
Vehicles with diesel engines TDI PD with DPF
Remove diesel particle filter → Engine; Rep. gr.26
–  Remove master brake cylinder → Chapter.
–  Remove the connecting hose between the intake manifold flap and the compressed air cooler → Engine; Rep. gr.21.
–  Remove suction hose between exhaust gas turbocharger and air filter → Engine; Rep. gr.23
–  Close the exhaust gas turbocharger e.g. with plugs from the plug set for engine -VAS 6122/40-.
–  Unscrew the screws for the connection pipe of the exhaust gas recirculation from the exhaust pipe → Engine; Rep. gr.21.
–  Remove induction pipe with mechanical exhaust gas recirculation valve and intake manifold flap → Engine; Rep. gr.23.
–  Remove intake manifold → Engine; Rep. gr.23.
Vehicles with diesel engines TDI PD without DPF:
–  Remove master brake cylinder → Chapter.
–  Remove the connecting hose between the intake manifold flap and the compressed air cooler → Engine; Rep. gr.21.
–  Remove suction hose between exhaust gas turbocharger and air filter → Engine; Rep. gr.23
–  Close the exhaust gas turbocharger e.g. with plugs from the plug set for engine -VAS 6122/40-.
–  Unscrew the screws for the connection pipe of the exhaust gas recirculation from the exhaust pipe → Engine; Rep. gr.21.
–  Remove induction pipe with mechanical exhaust gas recirculation valve and intake manifold flap → Engine; Rep. gr.23.
–  Remove intake manifold → Engine; Rep. gr.23.
Vehicles with diesel engines TDI CR
Remove diesel particle filter → Engine; Rep. gr.26.
–  Remove master brake cylinder → Chapter.
Continued for all vehicles:
  S10-0258
–  Unscrew screws of pendulum support -arrow B- and -arrow C-.
  S34-0882
–  Unscrew the screws -1- of the brake servo unit and remove.
Vehicles with diesel engines TDI CR
–  Remove toothed belt guard.
–  Attach the engine on the right to the supporting device -T30099-.
–  Partially lower the engine on the right vehicle side by approx. 60 to 70 mm → Engine; Rep. gr.10 or → Engine; Rep. gr.13, while doing so pay attention to all the lines.
–  Slightly pull the engine towards the front with the assistance of a second mechanic.
–  Swivel the brake servo unit with a pressure rod via the camshaft belt pulley.
Vehicles with diesel engines TDI PD:
–  Swivel the brake servo unit in the space above the exhaust gas turbocharger.
–  Slightly tilt the engine forward.
Continued for all vehicles:
–  Remove the brake servo unit from the vehicle.
Installing:
–  Installation is carried out in the reverse order.
  Note
If the battery earth strap is disconnected and connected, carry out certain additional operations → Electrical System; Rep. gr.27.
After installing, it is necessary to:
–  Bleeding brake system → Chapter.
–  Bleed clutch → Gearbox; Rep. gr.30.
Vehicles up to 11.05
–  Setting the brake light switch → Chapter.
  S47-0146
Tightening torques:
Master brake cylinder to brake servo unit
t  Use new nuts!
50 Nm
Screw for brake servo unit to foot controls25 Nm
Brake lines to master brake cylinder14 Nm

   

Brake line > < Removing and installing brake servo unit - Vehicles with left-hand drive