Assembly overview - hydraulic unit, brake servo/brake master cylinder Mark 60, vehicles from 10.2000 — 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 60, vehicles from 10.2000
Note
Complete brake master cylinders and brake servos can be renewed independently of each other.
Brake servo, left-hand drive vehicle
On petrol engines, the required vacuum is taken from the intake manifold.
In vehicles with a petrol engine and an automatic gearbox, the
vacuum pump for brakes
V192
is fitted additionally.
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
Brake assist system in brake servo
Checking function
Chapter
Separating from brake pedal
Chapter
Removing and installing
Chapter
.
Cap
Brake fluid reservoir, left-hand drive vehicle
Sealing plug
Moisten with brake fluid and press into brake fluid reservoir.
Retaining pin
Insert through brake master cylinder
Brake master cylinder, left-hand drive vehicle
Must not be repaired. If faulty, renew as a complete unit.
Brake line, 14 Nm
From primary piston circuit of brake master cylinder to hydraulic unit.
Brake line, 14 Nm
From hydraulic unit to front left brake caliper.
Brake line, 14 Nm
From hydraulic unit to front right brake caliper.
Brake line, 14 Nm
From secondary piston circuit of brake master cylinder to hydraulic unit.
ABS control unit
J104
Do not disconnect connector before vehicle self-diagnosis.
ABS hydraulic unit
N55
The hydraulic unit consists of the components:
Hydraulic pump
V64
Valve block (contains inlet and outlet valves).
Bracket
Hexagon nut, 20 Nm
Bolt, 8 Nm
Bolts, Torx socket head E5, 4 Nm
Brake line, 14 Nm
From hydraulic unit to rear left wheel brake cylinder/brake caliper
Brake line, 14 Nm
From hydraulic unit to rear right wheel brake cylinder/brake caliper
Brake fluid reservoir, right-hand drive vehicle
Sealing plug
Moisten with brake fluid and press into expansion chamber.
Bleeder valve
Retaining plate
Used to secure the wiring harness
Self-locking hexagon nut, 20 Nm
Brake master cylinder, right-hand drive vehicle
Must not be repaired. If faulty, renew as a complete unit.
Brake pressure sender 1
G201
Bolt
For securing brake fluid reservoir to brake master cylinder
Sealing ring
Renew.
Brake servo, right-hand drive vehicle
Seal
For brake servo.
Self-locking hexagon nut, 20 Nm
Boot
Ensure it is seated correctly, danger of suction noises
Mounting
Secured to edge of brake servo
Heat shield
Allocation
Electronic parts catalogue
Retaining plate
Used to secure the wiring harness
Sealing plug