Hydraulic unit, servo brake/brake cylinder - MK 60 assembly overview — VW

VW
Golf
1999
Golf
2007
Running gear
Brake systems
Edition
08.2013
Hydraulic unit, servo brake/brake cylinder - MK 60 assembly overview
The full brake cylinder and the servo brake can be independently replaced.
WARNING
Always replace self-locking nuts and bolts subject to angular torque
Brake servo
on gasoline engines, the vacuum required is removed from the intake manifold.
vehicles with diesel engines or automatic transmission have a vacuum pump install for creating vacuum.
some vehicles are also equipped with a
Brake vacuum pump
V192
check the operation
Chapter
remove and install
Chapter
correspondence
Electronic Parts Catalogue
check the operation
Press the brake pedal several times until the end with the engine stopped (This eliminates any remaining vacuum inside the device).
Now, press the brake pedal with medium strength and switch the engine on. With the servo brake operating correctly, this may be felt when the operator's foot is on the brake pedal (active amplification).
in case of faults, replace completely
check valve (in the vacuum hose)
Anchor
remove from the brake pedal
Chapter
.
remove and install
Chapter
Closing cover
Brake fluid reservoir
Sealing plug
moisten with brake fluid and press in the brake cylinder
Retaining pin
insert through the brake cylinder
Brake master cylinder
in vehicles with ABS/EDS/ASR/ESP the
Brake pressure sensor 1
G201
Chapter
is also installed
cannot be repaired. Where faults occur, replace completely.
Brake pipe connection
from the brake master cylinder/pressure plunger loop to the
ABS hydraulic unit
N55
Brake pipe connection
from the
ABS hydraulic unit
N55
to the left front brake caliper
Brake pipe connection
from the
ABS hydraulic unit
N55
to the right front brake caliper
Brake pipe connection
from the brake cylinder/floating plunger loop to the
ABS hydraulic unit
N55
ABS control unit
J104
remove and install
Chapter
do not disconnect the connector to the
ABS control unit
J104
before self-diagnosis
ABS hydraulic unit
N55
in the
ABS hydraulic unit
N55
the
ABS hydraulic pump
V64
and the intake and exhaust valves are verified, by means of self-diagnosis
the
ABS hydraulic pump
V64
and the valve block cannot be separated.
remove and install
Chapter
when replacing the
ABS hydraulic unit
N55
, close the old part with the plugs from the repair set
Support
Cover nut
20 Nm
Bolts
8 Nm
Screws, internal Torx E 5
4 Nm
Brake pipe connection
from the
ABS hydraulic unit
N55
to the wheel cylinder/left rear brake caliper
Brake pipe connection
from the
ABS hydraulic unit
N55
to the wheel cylinder/left rear brake caliper
Self-locking hexagonal nut
change
20 Nm
Mounting plate
used to fasten the harness
Thermal protection plate
correspondence
Electronic Parts Catalogue
Brake pressure sensor 1
G201
installed additionally only in vehicles with ABS/EDS/ASR/ESP
Chapter
Sealing plug
connection for vacuum hose
Sealing
for servo brake
Gasket
Self-locking hexagonal nut
change
20 Nm
Boot
ensure proper seating, aspiration noises may occur
Connect the brake pipes, brake cylinder pipes (Tandem) to the
ABS hydraulic unit
N55
Vehicles with ABS, ABS/EDS, ABS/EDS/ASR and ABS/EDS/ASR/ESP
A
Floating plunger loop
B
Pressure plunger loop
1
ABS hydraulic unit
N55
to the wheel cylinder/left rear brake caliper
2
ABS hydraulic unit
N55
to the left front brake caliper
3
ABS hydraulic unit
N55
to the left front brake caliper
4
ABS hydraulic unit
N55
to the wheel cylinder/left rear brake caliper