Removing and installing brake servo, LHD vehicles, bi-turbo diesel engine — VW

🧭 Before you start

Fits: VW Passat B8 (3G, 2014–)

• Opens: brake fluid

Don't miss

• Disconnect connector from brake fluid level warning contact F34(3), from vacuum sender G608(2) (if fitted) and from brake light switchF(1).
• After installing, bleed brake system and clutch.

📋 Procedure

1. Remove engine 10Removing and installing engine; Removing engine.
2. Draw off as much brake fluid as possible from brake fluid reservoir using brake filling and bleeding equipmentVAS 5234.
3. Disconnect connector from brake fluid level warning contact F34(3), from vacuum sender G608(2) (if fitted) and from brake light switchF(1).
4. Dissipate vacuum in brake servo by depressing brake pedal several times.
5. Disconnect brake lines from brake master cylinder and from hydraulic unit, and seal holes using sealing plugs1H0 698 311 A.

6. Fit dust caps of bleeder valves onto brake lines.
7. Unbolt upper section of insulation mat from plenum chamber bulkhead, and fold it over.
8. Unclip both brake lines to brake master cylinder from retainers, and lay them to one side.
9. Remove dash panel cover on driver side General body repairs, interior68Compartments and covers; Removing and installing dash panel cover on driver side.
10. Remove knee airbag (1)General body repairs, interior69Knee airbags; Assembly overview - knee airbag.
11. Remove footwell vent on driver side Heating, air conditioning system87Air duct; Assembly overview - air duct and air distribution in passenger compartment.
12. Separate brake pedal from brake servo .
13. Unscrew nuts (3 and 4) from brake servo.
14. Pull brake servo off plenum chamber bulkhead, applying force to separate bonded joint between brake servo, seal and plenum chamber bulkhead.
15. Carefully remove brake servo from the vehicle.
16. Unscrew nuts for brake master cylinder.
17. Remove heat shield, if fitted.
18. Carefully remove brake master cylinder from brake servo.
19. Remove adhesive residue from brake servo and plenum chamber bulkhead.
20. To do so, apply gentle heat from hot air blower to the adhesive residue, and pull it off.
21. Thoroughly clean surfaces.
22. Install in reverse order.
23. Connect brake pedal to brake servo .
24. After installing, bleed brake system and clutch.
25. Install engine 10Removing and installing engine; Installing engine.

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