Volkswagen Workshop Service and Repair Manuals

Removing and installing brake servo

Special tools and workshop equipment required

t	Sealing tool -T10249-

t	Torque wrench -V.A.G 1331-

t	Brake filling and bleeding equipment -VAS 5234-

Removing: –  Note or request radio code on vehicles with coded radio if necessary. –  Remove battery → Electrical system; Rep. gr.27. –  Remove engine control unit together with bracket and lay to side → 3 cyl. injection engine, toothed belt drive (4 valves); Rep. gr.24. –  Remove battery tray → Electrical system; Rep. gr.27. –  Remove air filter housing → 3 cyl. injection engine, toothed belt drive (4 valves); Rep. gr.24. –  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-. Only for vehicles with air conditioning system:

–  Disconnect connector -2- from high-pressure sender -G65--1-. Continuation for all models: –  Disconnect connector -A- from brake fluid level warning contact -F34-. –  Disconnect connector -B- from brake light switch -F-.

–  Then unclip wiring harness from brake master cylinder.

–  Disconnect return hose -C- for clutch master cylinder from brake fluid reservoir. –  Seal return hose -2- for clutch master cylinder -3- with sealing tool -T10249--1- or engine bung set -VAS 6122-. –  Tie return hose -2- in place above. –  Pull vacuum hose out of brake servo.

–  Mark and unscrew brake lines -A and B- from brake master cylinder and immediately seal brake lines with plugs from repair kit Part No. 1H0 698 311 A. –  Then slightly loosen brake lines -A and B- from hydraulic unit and lay to side.

–  Unscrew bolts -1- and remove footwell trim -2-. –  Separate brake pedal from brake servo → Chapter.

–  Remove hexagon nuts -arrows-. –  Carefully remove brake servo from the vehicle. –  If brake servo sticks in holes, loosen both remaining nuts on mounting bracket. –  Unscrew brake master cylinder from brake servo. –  Carefully remove brake master cylinder from brake servo. Installing: –  Install in reverse order. Observe following points when installing: –  Clip brake pedal to brake servo → Chapter. –  Bleed brake system → Chapter.

Specified torques:
Brake servo to pedal cluster and bulkhead t  Use new nuts.	25 Nm
Brake master cylinder to brake servo t  Use new nuts.	25 Nm
Brake lines to brake master cylinder	14 Nm