Hydraulic unit, servo brake/master cylinder - Bosch ABS assembly overview of assembly — VW

VW
Gol
2009
Saveiro
2010
Voyage
2009
Running gear
Brake systems
Edition
08.2013
Hydraulic unit, servo brake/master cylinder - Bosch ABS assembly overview of assembly
WARNING
Always replace self-locking nuts and bolts subject to angular torque
The brake master cylinder and the brake servo may be independently replaced.
ABS control unit
J104
Remove and install
ABS hydraulic unit
N55
along with
ABS control unit
J104
Chapter
.
ABS hydraulic unit
N55
The
ABS reflux pump
V39
and the coupled valves cannot be separated.
When replacing the hydraulic unit, seal the old part with the plugs from the repair set number ET 1H0 698 311 A.
Remove and install
ABS hydraulic unit
N55
along with
ABS control unit
J104
Chapter
.
Brake pipe connection
Hydraulic unit for right front brake caliper.
Identification in the hydraulic unit
VR
.
14 Nm.
Brake pipe connection
Hydraulic unit for left rear brake caliper.
Identification in the hydraulic unit
HL
.
14 Nm.
Brake pipe connection
Hydraulic unit for right rear brake caliper.
Identification in the hydraulic unit
HR
.
14 Nm.
Brake pipe connection
Hydraulic unit for left front brake caliper.
Identification in the hydraulic unit
VL
.
14 Nm.
Brake master cylinder connection
Brake master cylinder/floating plunger circuit for the hydraulic unit.
Identification in the hydraulic unit
HZ1
.
14 Nm.
Brake master cylinder connection
Brake master cylinder/floating plunger circuit for the hydraulic unit.
Identification in the hydraulic unit
HZ2
.
14 Nm.
Sealing
to servo brake.
Replace if damaged.
Brake servo
On petrol engines, the vacuum required is removed from the intake manifold.
On diesel engines, a vacuum pump is installed to create vacuum.
Operation checking:
Press the brake pedal several times until the end with the engine stopped (This eliminates any remaining vacuum inside the device).
Now, keep the brake pedal pressed in the braking position with medium force and start the engine. When the brake servo is working properly, this can be felt with a foot on the brake pedal (the amplification is active).
In case of faults, replace completely.
Flexible vacuum tube
Chapter
.
Separate from the brake pedal
Chapter
.
Remove and install
Chapter
.
Self-locking hex head nut
Replace
4 units.
28 Nm.
Sealing ring
Replace it if damaged.
Self-locking hex head nut
Replace
2 units.
25 Nm.
Brake master cylinder
Cannot be repaired. Where faults occur, replace completely.
Remove and install
Chapter
.
Retaining pin for the brake fluid reservoir
Insert through the master brake cylinder to lock to the tank.
Sealing plug
Moisten with brake fluid and press in the brake cylinder.
Sealing plug
Connection to flexible vacuum tube.
Brake fluid reservoir
Plug
Bolts
2 units.
8 Nm.
Self-locking hex head nut
Replace
2 units.
20 Nm.
ABS upper support
Stud
2 units.
Stud welded to the body.
Self-locking hex head nut
Replace
1 unit.
20 Nm
Stud
1 unit.
Stud welded to the body
ABS lower support
WARNING
Whenever removed, bleed the break system
Chapter
.