Removing and installing brake servo — VW

🧭 Before you start

Fits: platform codes AU1, BX5

• Opens: brake fluid, clutch fluid
• Renewed: gasket

Don't miss

• Release connector (3), and pull it off brake fluid level warning contact F34.
• The brake servo only has the additional bonded joint at the seal when originally assembled at the factory.The adhesive bond between the brake servo and the plenum chamber bulkhead does not need to be renewed, but the gasket does.
• Operate adhesive strip removerVAS 6349 at low speed, working against direction of rotation.
• Seals (2) must be located in supply hose (1) leading to clutch master cylinder.

📋 Procedure

1. If vehicle has a coded radio, note radio code or, if necessary, request it.
2. Disconnect battery Electrical system27Battery; Disconnecting and reconnecting battery.
3. Remove battery Electrical system27Battery; Removing and installing battery.
4. Remove engine cover panel 10Engine cover panel; Removing and installing engine cover panel.
5. Unclip vacuum lines from air intake hose.

6. Open clamps (1) and (2).
7. Remove air intake hose.
8. Remove air filter housing 23Air filter; Removing and installing air filter housing.
9. Open clamps (2) and (3).
10. Remove air ducting hose (1).
11. Remove air filter housing 24Air filter; Removing and installing air filter housing.
12. Remove battery tray Electrical system27Battery; Removing and installing battery tray.
13. Place sufficient lint-free cloths in area of engine and gearbox.
14. Draw off as much brake fluid as possible from brake fluid reservoir using brake filling and bleeding equipmentVAS 5234.
15. Pull return hose (2) for clutch sender cylinder (3) off brake fluid reservoir (4).
16. Seal supply hose (2) for clutch master cylinder (3) with sealing tool T10249(1) or engine bung setVAS 6122.
17. Raise and tie return hose (2) in place.
18. If fitted, release connector (2), and pull it off vacuum sender G608.
19. Release connector (3), and pull it off brake fluid level warning contact F34.
20. Release connector (1), and pull it off brake light switchF.
21. Dissipate vacuum in brake servo by depressing brake pedal several times.
22. Pull vacuum hose out of brake servo.
23. Unscrew brake lines (A) and (B) from brake master cylinder.
24. Immediately seal brake lines and open connections with sealing plugs from repair kit1H0 698 311 A or suitable plugs from engine bung setVAS 6122.
25. Remove selector cable and cable support bracket from gearbox 34Selector mechanism; Assembly overview - selector mechanism.
26. Remove clutch cable and cable support bracket from gearbox 34Selector mechanism; Assembly overview – selector mechanism.
27. Remove dash panel end cover on driver side General body repairs, interior70Dash panel; Removing and installing dash panel end cover.
28. Remove footwell cover on driver side General body repairs, interior68Compartments/covers.
29. Remove centre console cover on driver side General body repairs, interior68Centre console; Removing and installing centre console cover.
30. Remove storage compartment on driver side General body repairs, interior68Compartments/covers.
31. Remove dash panel cover on driver side General body repairs, interior68Compartments and covers; Removing and installing dash panel cover on driver side.
32. Remove knee airbag General body repairs, interior69Knee airbags; Assembly overview - knee airbag.
33. Remove footwell vent on driver side Heating, air conditioning system87Air duct; Assembly overview - air duct and air distribution in passenger compartment.
34. Remove crash bar General body repairs, interior70Dash panel central tube; Assembly overview – dash panel central tube.
35. Remove data bus diagnostic interface J533, and lay it to one side Electrical system97Control units; Removing and installing data bus diagnostic interface J533.
36. Separate brake pedal from brake servo .
37. Unscrew bolt (1) and fold footwell covering (2) in direction of arrow towards vehicle interior.
38. Unscrew nuts (3) and (4) from brake servo.
39. Pull brake servo off plenum chamber bulkhead, applying force to separate bonded joint between brake servo, seal and plenum chamber bulkhead.
40. Carefully remove brake servo from the vehicle.
41. Unscrew nuts for brake master cylinder.
42. Remove heat shield, if fitted.
43. Carefully remove brake master cylinder from brake servo. [Note: The brake servo only has the additional bonded joint at the seal when originally assembled at the factory.The adhesive bond between the brake servo and the plenum chamber bulkhead does not need to be renewed, but the gasket does.]
44. Remove all adhesive residue from the plenum chamber bulkhead and (if applicable) from the brake servo. Use adhesive strip removerVAS 6349 with a drill, cordless screwdriver or grinder for this purpose.
45. Apply gentle heat from hot air blower to the adhesive residue, and pull it off.
46. Operate adhesive strip removerVAS 6349 at low speed, working against direction of rotation.
47. Thoroughly clean surfaces.
48. Renew gasket .
49. Carefully insert brake servo and tighten nuts.
50. Connect brake pedal to brake servo .
51. Bleed brake system .
52. Seals (2) must be located in supply hose (1) leading to clutch master cylinder.
53. Bleed clutch mechanism 30Clutch mechanism; Bleeding clutch mechanism.

Other VW procedures

• Removing engine · 41 torque figures
• Removing and installing camshaft · 47 torque figures
• Adjusting valve timing · 83 torque figures
• Removing and installing camshafts · 39 torque figures
• Removing and installing coolant pump · 53 torque figures
• Removing and installing gaiter with gear knob and noise insulation, Golf
• Repairing gearbox housing and clutch housing
• Removing and installing fuel gauge sender of fuel delivery unit in fuel tank
• Removing toothed belt, vehicles with old toothed belt tensioner
• Automatic gearbox 01M — Dismantling and assembling freewheel with -B1- piston