Hydraulic unit, brake servo/brake master cylinder - Assembly overview, Mark 60 — VW

VW
Polo
2002
Running gear
Brake system
Edition
10.2004
Hydraulic unit, brake servo/brake master cylinder - Assembly overview, Mark 60
Master cylinder and brake servo can be independently renewed.
Brake pipe connection
Master cylinder of brake/pressure piston circuit for hydraulic unit.
Hydraulic unit identification -DK-.
Brake pipe connection
Hydraulic unit to front left brake caliper.
Hydraulic unit identification -VL-.
Brake pipe connection
Hydraulic unit to front right brake caliper.
Hydraulic unit identification -VR-.
Brake pipe connection
Master cylinder of brake/pressure piston circuit for hydraulic unit.
Hydraulic unit identification -SK-.
Brake fluid tank
Plug
Sealing plug
Wet with brake fluid and press brake master cylinder.
Brake servo
On petrol engines the vacuum required is taken from the intake manifold.
On diesel engines an exhauster is installed to create the required vacuum.
Functional check.
With engine switched off, depress brake pedal firmly several times (to exhaust the vacuum in the unit).
Now depress brake pedal with average foot pressure, hold and start engine. If the servo unit is working properly, the pedal will be felt to give slightly under foot (servo assistance becomes effective.
Step on brake pedal repeatedly with engine off (That eliminates vacuum remaining in the equipment).
Then hold brake pedal on braking position applying medium pressure and switch on engine. Proper operation of brake servo can be noticed on the pedal (rise is active).
If faulty renew complete.
Non return valve (in vacuum hose)
Anchor
.
Separate from brake pedal
Chapter
.
Dismantling and assembling
Chapter
.
Seal
To servo brake.
Self locking hexagon nut, 20 Nm
Master cylinder
Cannot be repaired. If faulty renew complete.
Dismantling and assembling.
Chapter
Brake fluid tank securing bolt
Insert through brake master cylinder.
Sealing plug
Connection for vacuum hose.
O-ring
Renew
Self locking hexagon nut, 28 Nm
Bolts, 8 Nm
Self locking hexagon nut, 20 Nm
Bracket
Stud bolt
Stud bolt welded to body.
Self locking hexagon nut, 20 Nm
Bracket
Brake pipe connection
Hydraulic unit to rear left wheel cylinder/caliper.
Hydraulic unit identification -HL-.
Brake pipe connection
Hydraulic unit to rear right wheel cylinder/caliper.
Hydraulic unit identification -HR-.
Stud bolt
Stud bolt welded to body.
ABS hydraulic unit
N55
with
ABS with EDL control unit
J104
.
The
ABS hydraulic pump
V64
and the inlet/outlet valves in the hydraulic unit are checked by selfdiagnosis.
ABS hydraulic pump
V64
and valve set cannot be separated.
Removing and installing
Chapter
When renewing the hydraulic unit, close old part with plugs from
repair set
ET 1H0 698 311 A
.
Removing and installing
ABS with EDL control unit
J104
Chapter
Connect brake, brake master cylinder (Tandem) pipes to hydraulic unit
Anchor
Vehicles with ABS and ABS/EDL/TCS
A
Floating piston circuit
Hydraulic unit identification -SK-
B
Pressure piston circuit
Hydraulic unit identification -DK-
1
Hydraulic unit to front left brake caliper
Hydraulic unit identification -VL-
2
Hydraulic unit to front right brake caliper
Hydraulic unit identification -VR-
3
Hydraulic unit to rear right wheel cylinder/brake caliper
Hydraulic unit identification -HR-
4
Hydraulic unit to rear left wheel cylinder/brake caliper
Hydraulic unit identification -HL-