New Beetle L4-2.0L (AZG) (2003)
Hydraulic Control Assembly - Antilock Brakes: Service and Repair
Hydraulic Unit, Brake Booster/Brake Master Cylinder Overview
Hydraulic unit, brake booster/brake master cylinder -assembly overview Mark 60
Note: Complete master cylinder and brake booster can be replaced independently of each other.
1. Brake booster, left-hand drive
On gasoline engines the vacuum required is taken from the intake manifold.
On Diesel engines a vacuum pump is installed to create the required vacuum.
On some vehicles an electrical brake system vacuum pump -V192- is installed
With engine not running, depress brake pedal firmly several times (to exhaust the vacuum in the module).
Now depress brake pedal with average foot pressure, hold and start engine. If the booster module is working properly, the pedal will be felt
to give slightly under foot (booster assistance becomes effective).
2. Sealing cap
3. Brake fluid reservoir, left-hand drive (LHD)
4. Sealing plugs
Moisten with brake fluid and install into brake fluid reservoir
5. Retaining pin
Insert through brake master cylinder
6. Brake master cylinder, left-hand drive (LHD)
Must not be repaired. If faulty, replace complete.
7. Brake line
Brake master cylinder (primary circuit) to hydraulic unit
8. Connection for brake line
Hydraulic unit to left front brake caliper
9. Connection for brake line
Hydraulic unit to right front brake caliper
10. Brake line
Brake master cylinder (secondary circuit) to hydraulic unit
11. Control module
Do not disconnect connector before performing On Board Diagnosis (OBD)