Assembly overview - hydraulic unit, brake servo/brake master cylinder Mark 20 IE, vehicles up to 09.2000 — VW

VW
New Beetle
1999
New Beetle Cabrio
2003
Running gear
Brake systems
Edition
02.2012
Assembly overview - hydraulic unit, brake servo/brake master cylinder Mark 20 IE, vehicles up to 09.2000
Note
Complete brake master cylinders and brake servos can be renewed independently of each other.
Brake servo
With wiring harness,
brake pressure sender 1
G201
Item
and
brake pressure sender 2
G214
Item
On petrol engines, the required vacuum is taken from the intake manifold.
On diesel engines an vacuum pump is installed to generate vacuum.
Functional check:
With engine switched off, depress brake pedal firmly several times. (This will release the vacuum in the 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.
If faulty, renew as a complete unit.
Non-return valve (in vacuum hose)
Checking function
Anchor
Separating from brake pedal
Chapter
Removing and installing
Chapter
.
Mounting
Secured to edge of brake servo
Used to mount connector housing
Item
Cap
Brake fluid reservoir
Sealing plug
Moisten with brake fluid and press into brake fluid reservoir.
Retaining pin
Insert through brake master cylinder
Brake master cylinder
Must not be repaired. If faulty, renew as a complete unit.
Retaining plate
Used to secure the wiring harness
Self-locking hexagon nut, 20 Nm
Cap nut, 20 Nm
Fitted bolt, 8 Nm
Bracket
ABS hydraulic unit
N55
The hydraulic unit consists of the components:
ABS hydraulic pump
V64
Valve block (contains inlet and outlet valves).
ABS control unit
J104
Do not disconnect connector before vehicle self-diagnosis.
Brake line, 14 Nm
From hydraulic unit to front left brake caliper.
Brake line, 14 Nm
From hydraulic unit to rear right brake caliper.
Brake line, 14 Nm
From hydraulic unit to rear left brake caliper.
Brake line, 14 Nm
From hydraulic unit to front right brake caliper.
Brake line, 14 Nm
From primary piston circuit of brake master cylinder to hydraulic unit.
Brake line, 14 Nm
From secondary piston circuit of brake master cylinder to hydraulic unit.
Self-locking hexagon nut, 20 Nm
Heat shield
Only on vehicles with at least a 110 kW motor
Connector housing
Brake pressure sender 1
G201
Removing and installing
Chapter
.
Brake pressure sender 2
G214
Removing and installing
Chapter
.
Sealing ring
Renew.
Wiring harness
Sealing plug
Vacuum hose
Fit in brake servo.
Self-locking hexagon nut, 20 Nm
Seal
For brake servo.
Boot
Ensure it is seated correctly, danger of suction noises
Connecting brake lines from tandem brake master cylinder to hydraulic unit
Vehicles with ABS/EDL/TCS/ESP
A
Secondary piston circuit
B
Primary piston circuit