Volkswagen Golf Service & Repair Manual: Removing and installing brake master cylinder, LHD vehicles

Special tools and workshop equipment required

Torque wrench -V.A.G 1331-

Removing and installing brake master cylinder, LHD vehicles

Torque wrench -V.A.G 1410-

Tool inserts (11 mm) -V.A.G 1331/2-

Brake filling and bleeding equipment -VAS 5234-

Sealing plug repair kit -1H0 698 311 A-

Removing:

Observe safety precautions when working in the area of high-voltage components → Chapter.
Observe the risk classification of the high-voltage system → Electric drive; Rep. gr.00.

Danger to life due to high voltage

The high-voltage system is under high voltage. If high-voltage components are damaged, there is a risk of severe or fatal injury due to electric shock.

Carry out visual inspection of high-voltage components and cables.
Never use cutting or forming tools, or any others with sharp edges.
Never use heat sources such as welding, soldering, thermal bonding or hot air.

Disconnect battery → Electrical system; Rep. gr.27.
Remove power and control electronics for electric drive -JX1- → Electrical system; Rep. gr.93.
Remove bracket for power and control electronics for electric drive -JX1- → Electrical system; Rep. gr.93.
Place sufficient lint-free cloths in area of engine, subframe and gearbox.
Draw off as much brake fluid as possible from brake fluid reservoir using brake filling and bleeding equipment -VAS 5234-.

Release and pull off connector -1- for brake fluid level warning contact -F34--2- on brake fluid reservoir -3-.

Unscrew bolt -2- and carefully pull off brake fluid reservoir -1- upwards.

Mark position of brake lines -2 to 4- on brake master cylinder -1-.
Unscrew brake lines -2 to 4- from brake master cylinder -1-.
Seal threaded holes immediately using sealing plugs -1H0 698 311 A-.
Fit dust caps from the bleeder valves onto brake line.

Remove bolts -arrows-.
Carefully take brake master cylinder -1- out of brake servo.

Installing:

Install in reverse order. Note the following points:

Thoroughly clean threaded hole for bolts → Item.
When assembling brake master cylinder with brake servo, make sure push rod is properly positioned in brake master cylinder.
When assembling brake master cylinder with brake servo, make sure seal → Item is seated correctly.
Fit sealing plugs onto brake fluid reservoir → Item.
Moisten sealing plugs → Item with brake fluid before pressing brake fluid reservoir into brake master cylinder.
Bleed brake system → Chapter.
Subsequently bleeding the brake system → Chapter.
Perform basic setting for electromechanical brake servo → Vehicle diagnostic tester.

Removing and installing brake master cylinder, LHD vehicles

Special tools and workshop equipment required

Torque wrench -V.A.G 1331-

Torque wrench -V.A.G 1410-

Tool inserts (11 mm) -V.A.G 1331/2-

Brake filling and bleeding equipment -VAS 5234-

Sealing plug repair kit -1H0 698 311 A-

Removing:

Danger to life due to high voltage

Installing:

Install in reverse order. Note the following points:

Specified torques

→ Chapter „Assembly overview - brake servo/brake master cylinder, LHD vehicles“

→ Chapter „Assembly overview – Brake system pressure accumulator -VX70-“

→ Electrical system; Rep. gr.93

→ Electrical system; Rep. gr.27.

Test yourself