Removing and installing brake pedal/brake servo/brake master cylinder — VW
Removing and installing brake pedal/brake servo/brake master cylinder on VW: factory workshop procedure. Full factory text, tools and checks.
Workshop procedure for VW — the factory write-up, straight from real workshop data.
📋 Procedure
ℹ️ Torque figures below come verbatim from workshop data — always cross-check against your vehicle's factory manual before final tightening.
Warning!
The brake pedal travel must not be restricted by additional floor coverings.
Grease all mountings before installing with grease Part No. G 000 602.
Cap
Brake fluid reservoir
With strainer
Brake fluid level warning switch is integrated into reservoir
Sealing plug
Moisten with brake fluid and press into reservoir
Hexagon nut, 20 Nm
Brake master cylinder
Cannot be repaired. If faulty, renew complete.
Bleeding => Page
47-29
Sealing ring
Renew
Securing clip
Ensure seated securely
Pin
Grease with G 000 602
Self-locking hexagon nut, 25 Nm
Renew
Brake servo push rod clevis
Tandem brake servo
Before removing tandem brake servo unit, remove battery and disconnect brake pipes
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).
If faulty renew complete.
Non-return valve is integrated into vacuum pipe, checking Fig.
1
Seal
For tandem brake servo
Securing clip
Brake pedal return spring
Brake pedal mounting bush
Brake pedal
Brake pedal pivot pin
Brake light switch
Before installing brake light switch, connect brake pedal to brake servo push rod
Before installing pull plunger out completely
Guide switch through mounting hole and secure by turning clockwise 90°
Hexagon bolt, 25 Nm
Mounting bracket
Hexagon bolt, 25 Nm
Mounting plate
Bulk head
Fig.1
Checking non-return valve -A-
Air must pass through in direction of arrow.
In the opposite direction the valve must remain closed.
Observe correct installation position.
The illustration shows the vacuum pipework of 111 kW TDI engine. The vacuum pipework differs according to engine version, therefore allocate using parts catalogue.
TorqFix answers live for your specific car — tell it the engine code and it serves the matching sequence, torque figures and wiring for that exact variant.
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Who makes these pages, and how
TorqFix was built by a mechanic — after a 2,700 km drive with five roadside repairs that no diagnostic tool could explain.
The figures on this page come from manufacturer workshop documentation and are shown as they are. The page is assembled automatically from that data — it is not written by an AI. The AI works in the chat, where it answers for your specific car. It writes nothing here.
Variants of the same model differ. Cross-check torque against the factory manual for your engine before final tightening.
Seen a figure that does not match your manual? Write to us — we correct it and note when. support@torqfix.com
The story behind TorqFix →Workshop data on this page last updated 20 Sep 2026.