Removing and installing brake servo, RHD vehicles with diesel engine

Hose clamps, up to 25 mm -3094-

Hose clip pliers -V.A.G 1921-

Torx screwdriver bit T30 -T10405-

Fitting location of brake servo in RHD vehicles:

Removing

• If vehicle has a coded radio, note radio code or, if necessary, request it.
• Remove engine cover panel → Rep. gr.10.

• Pull off fuel supply lines -1- and -2-.
• Separate plug-in connectors → Rep. gr.20.
• Unclip fuel lines -1- and -2- from retainer -arrow- on coolant reservoir -3-.

• Remove securing bolts -2-.
• Unscrew nut -1-.

• Open retainer -arrow- and unclip fuel lines -1-.
• Then lay fuel filter to one side.

• Release electrical connector -1- and pull off.
• Release catches using a screwdriver -arrow-.
• Place coolant expansion tank onto engine.

• Remove battery tray -1- → Electrical system; Rep. gr.27.
• Remove noise insulation → General body repairs, exterior; Rep. gr.66.
• Remove subframe with steering rack → Running gear, axles, steering; Rep. gr.40.
• Remove front exhaust pipe → Rep. gr.26.
• Drain coolant → Rep. gr.19.
• Remove left coolant pipes → Rep. gr.19.
• Remove rear coolant pipe → Rep. gr.19.
• Remove exhaust gas recirculation cooler → Rep. gr.26.

• Remove exhaust gas temperature senders -1- and -2- → Rep. gr.26.

• Remove Lambda probe -arrow- → Rep. gr.23.
• Remove emission control module → Rep. gr.26.

Vehicles with air conditioning:

• Evacuate refrigerant circuit → Heating, air conditioning; Rep. gr.00.
• Remove refrigerant lines with internal heat exchanger → Heating, air conditioning; Rep. gr.87.

Vehicles with manual gearbox:

• If present, remove heat shield.
• To do so, remove clamping washer -4- from plenum chamber bulkhead.
• Open snaps -1- to -3- on heat shield.

• Pull return hose -2- for clutch sender cylinder -3- off brake fluid reservoir -4-.
• Seal return hose -2- for clutch master cylinder -3- with sealing tool -T10249--1- or hose clips to 25 mm -3094-.
• Raise and tie return hose -2- in place.

Continuation for all models:

• Place sufficient lint-free cloths in area of engine.
• Draw off as much brake fluid as possible from brake fluid reservoir using brake filling and bleeding equipment -VAS 5234-.

• Remove heat shield -1- if present.
• Also unscrew screw -3- with Torx screwdriver bit T30 -T10405-.
• Pull heat shield -1- upwards out of retainers -arrows- on brake fluid reservoir -2-.

• Release connector -1- and pull off brake light switch -F--2-.

• Release electrical connector -2- for brake fluid level warning contact -F34- and pull it off brake fluid reservoir -1-.

• Pull out spreader rivet -3- in -direction of arrow-.
• Pull brake fluid reservoir -1- upwards off brake master cylinder -2-

• Dissipate vacuum in brake servo by depressing brake pedal several times.
• Pull vacuum line -4- out of brake servo -1-.

• Unbolt brake lines -2- from brake master cylinder -1-.
• Detach brake lines from brake master cylinder and seal brake lines with plugs from repair kit Part No. 1H0 698 311 A.
• Remove nuts -arrows-.
• Remove heat shield -3-.
• Carefully remove brake master cylinder from brake servo.
• Remove dash panel end cover on driver side → General body repairs, interior; Rep. gr.70.
• Remove footwell cover on driver side → General body repairs, interior; Rep. gr.68
• Remove storage compartment on driver side → General body repairs, interior; Rep. gr.68
• Remove dash panel cover on driver side → General body repairs, interior; Rep. gr.68.
• Remove knee airbag → General body repairs, interior; Rep. gr.69.

• Remove footwell vent -1- on driver side → Heating, air conditioning system; Rep. gr.87.
• To do this, unscrew bolt -2- and remove footwell vent on driver side -1-.
• Unbolt crash bar for brake pedal and lay it to one side → General body repairs, interior; Rep. gr.70.
• Separate brake pedal from brake servo → Chapter.

• Remove nuts -arrows- from mounting bracket.
• Remove brake servo downwards.

Installing

Install in reverse order of removal, observing the following:

• Remove all adhesive residues from the plenum chamber bulkhead and (if applicable) from the brake servo. Use adhesive strip remover -VAS 6349- and a drill, cordless screwdriver or grinder for this purpose.
• Operate adhesive strip remover -VAS 6349- at low speed, working against direction of rotation.
• Carefully insert brake servo and tighten nuts.
• When assembling brake master cylinder with brake servo, make sure push rod is properly positioned in brake master cylinder.
• When joining brake master cylinder to brake servo, make sure seal → Item is properly seated.
• Ensure that seals → Item are correctly seated in brake master cylinder.
• Moisten sealing plugs → Item with brake fluid before pressing brake fluid reservoir into brake master cylinder.
• Connect brake pedal to brake servo → Chapter.
• Fill coolant → Rep. gr.19.
• Bleed brake system → Chapter.

Vehicles with manual gearbox:

• Bleed clutch mechanism → Rep. gr.30.

Vehicles with air conditioning:

• Charge refrigerant circuit → Heating, air conditioning; Rep. gr.00.

Specified torques

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

→ Chapter „Removing and installing brake master cylinder, RHD vehicles“

Crash bar → General body repairs, interior; Rep. gr.70.

Footwell vents → Heating, air conditioning system; Rep. gr.87.

Knee airbag → General body repairs, interior; Rep. gr.69.

Covers on driver side → General body repairs, interior; Rep. gr.68

Subframe → Running gear, axles, steering; Rep. gr.40

Cooling system → Rep. gr.19.

Emission control → Rep. gr.26.

Exhaust gas recirculation → Rep. gr.26

Exhaust system → Rep. gr.26

Toothed belt guard → Rep. gr.15

Exhaust gas temperature sender → Rep. gr.26

Fuel filter → Rep. gr.20

Air conditioning → Heating, air conditioning; Rep. gr.87

Battery → Electrical system; Rep. gr.27

Noise insulation → General body repairs, exterior; Rep. gr.66.

Front bleed valves → Chapter „Assembly overview - front brake caliper“

Rear bleed valves → Chapter „Assembly overview - rear brake caliper“