Removing and installing brake servo, left-hand drive — VW

🧭 Before you start

Fits: platform code BE1

• Opens: brake fluid
• Renewed: gasket between brake servo

Don't miss

• Never use cutting or forming tools, or any other sharp-edged tools.
• Never use heat sources such as welding, brazing, soldering, hot air or thermal bonding equipment.
• Release and pull off connector (1) for brake fluid level warning contact F34(2) on brake fluid reservoir (3).
• A second mechanic is required for further removal.
• While doing so, the bonded joint between the brake servo and the plenum chamber bulkhead will be separated.Make sure not to bend the brake lines.If the bonded joint cannot be separated, unscrew the nuts.

📋 Procedure

1. Observe safety precautions when working in the vicinity of high-voltage components .
2. Observe the risk category of the high-voltage system Electric drive00Risk category of the high-voltage system.
3. Carry out visual inspection of high-voltage components and cables.
4. Never use cutting or forming tools, or any other sharp-edged tools.
5. Never use heat sources such as welding, brazing, soldering, hot air or thermal bonding equipment.

6. Read and note code of brake servo control unit J539.
7. Remove battery Electrical system27Battery; Removing and installing battery.
8. Remove battery tray (1)Electrical system27Battery; Removing and installing battery tray.
9. Release and pull off connector (1) for brake fluid level warning contact F34(2) on brake fluid reservoir (3).
10. Release connector (2), and pull it off brake servo (1).
11. Pull locking slide (red) (1) towards front.
12. Press release tab (3) on connector (4).
13. Release latch (2), and pull connector (4) off brake servo (5).
14. Place sufficient lint-free cloths in area of engine, subframe and gearbox.
15. Remove dash panel trim in driver footwell General body repairs, interior68Storage compartments/covers; Assembly overview – dash panel trim on driver side.
16. Fold down floor covering (1) in (direction of arrow).
17. Loosen nuts (3 and 4) on brake servo as far as possible. [Note: A second mechanic is required for further removal.]
18. Depress brake pedal firmly and hold.
19. Have a second mechanic grasp brake servo and pull it towards front. [Note: While doing so, the bonded joint between the brake servo and the plenum chamber bulkhead will be separated.Make sure not to bend the brake lines.If the bonded joint cannot be separated, unscrew the nuts.]
20. Separate brake pedal from brake servo .
21. Draw off as much brake fluid as possible from brake fluid reservoir using brake filling and bleeding equipmentVAS 5234.
22. Mark position of brake lines (2 to 4) on brake master cylinder (1).
23. Unscrew brake lines (2 to 4) from brake master cylinder (1).
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. Unscrew brake line (2) from brake system pressure accumulatorVX70, and remove it.
26. Unscrew nuts (3 and 4) from brake servo.
27. If brake servo gets jammed in holes, loosen both remaining nuts (1 and 2) on the mounting bracket.
28. Carefully pull brake servo off plenum chamber bulkhead.
29. Carefully remove brake servo from the vehicle.
30. Remove adhesive residue (arrows) from brake servo (2) and plenum chamber bulkhead (1).
31. To do so, apply gentle heat from hot air blower to the adhesive residue, and pull it off.
32. Thoroughly clean surfaces.
33. Renew gasket between brake servo and plenum chamber bulkhead .
34. Carefully insert brake servo and tighten nuts hand-tight.
35. Connect brake pedal to brake servo .
36. Bleed brake system .
37. Bleed brake system .
38. Code brake servo control unit J539.
39. Perform basic setting for electromechanical brake servo .

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