Assembly overview - brake servo/brake master cylinder, LHD vehicles

Note Only use new brake fluid conforming to VW standard (VW 501 14).

1 -	Self-locking hexagon nut

Always renew after removing

Bolting sequence → Fig.

25 N·m

2 -	Pedal cluster with mounting bracket

3 -	Plenum chamber bulkhead

4 -	Self-locking hexagon nut

Always renew after removing

23 N·m

5 -	Brake master cylinder

Cannot be repaired. If faulty, renew as a complete unit.

Removing and installing → Chapter

6 -	Brake light switch -F-

Removing and installing → Chapter

7 -

Bolt

8 N·m

8 -	Brake line

From secondary piston circuit of brake master cylinder to hydraulic unit.

14 N·m

9 -	Brake line

From primary piston circuit of brake master cylinder to hydraulic unit.

14 N·m

10 -	Sealing plug

Moisten with brake fluid and press into brake fluid reservoir.

11 -	Brake fluid level warning contact --F34--

12 -	Brake fluid reservoir

Securing bolt, 8 N·m

13 -	Vacuum hose

With non-return valve

Fit in brake servo

On some vehicles with petrol engines, vacuum sender -G608- is installed in brake servo → Chapter

14 -

Cap

15 -

Seal

Vacuum hose for brake servo

16 -	Sealing ring

Between brake master cylinder and brake servo

17 -	Brake servo

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.

Replace completely in the event of a fault (before doing so, check brake servo vacuum system) → Chapter

Removing and installing → Chapter

18 -

Seal

Renew

Bonded (only when originally assembled at factory)

Bonded joint at brake servo and plenum chamber bulkhead does not have to be renewed

Bolting sequence: