Removing and installing brake servo, LHD vehicles, turbodiesel 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. If vehicle has a coded radio, note radio code or, if necessary, request it.
2. Remove engine cover panel.
3. Disconnect battery Electrical system27Battery; Disconnecting and reconnecting battery.
4. Remove battery Electrical system27Battery; Removing and installing battery.
5. Remove battery tray Electrical system27Battery; Removing and installing battery tray.

6. If installed above left assembly mounting, remove air filter carrier 24Air filter; Removing and installing air filter housing.
7. Unbolt jump start box together with bracket, and lay it to one side.
8. Remove air intake hose, air filter housing and intake hose 23Air filter; Removing and installing air filter housing.
9. Place sufficient lint-free cloths in area of engine and gearbox.
10. Draw off as much brake fluid as possible from brake fluid reservoir using brake filling and bleeding equipmentVAS 5234.
11. Pull off supply hose (1) for clutch master cylinder, seal it using sealing tool T10249 and tie it up, or clamp off supply hose (1) for clutch master cylinder using commercially available tool, e.g. Hazet 4590, and pull it off.
12. Disconnect connector from brake fluid level warning contact F34(3), from vacuum sender G608(2) (if fitted) and from brake light switchF(1).
13. Dissipate vacuum in brake servo by depressing brake pedal several times.
14. Pull vacuum hose (1) out of brake servo (2).
15. Remove air intake hose (2) between air intake pipe (1) and turbocharger 21Charge air system; Assembly overview - charge air system.
16. Unbolt resonator (1)(arrows).
17. Remove engine lifting eye from cylinder head 15Cylinder head; Assembly overview - cylinder head.
18. Remove selector cable and cable support bracket from gearbox 34Selector mechanism; Assembly overview - selector mechanism.
19. Unbolt connector strip with connectors (1 to 4) from plenum chamber bulkhead, pull it off, and lay it to one side.
20. Disconnect brake lines from brake master cylinder and from hydraulic unit, and seal holes using sealing plugs1H0 698 311 A.
21. Fit dust caps of bleeder valves onto brake lines.
22. Unbolt upper section of insulation mat from plenum chamber bulkhead, and fold it over.
23. Unclip both brake lines to brake master cylinder from retainers, and lay them to one side.
24. Remove dash panel cover on driver side General body repairs, interior68Compartments and covers; Removing and installing dash panel cover on driver side.
25. Remove knee airbag (1)General body repairs, interior69Knee airbags; Assembly overview - knee airbag.
26. Remove footwell vent on driver side Heating, air conditioning system87Air duct; Assembly overview - air duct and air distribution in passenger compartment.
27. Separate brake pedal from brake servo .
28. Unscrew nuts (3 and 4) from brake servo.
29. Pull brake servo off plenum chamber bulkhead, applying force to separate bonded joint between brake servo, seal and plenum chamber bulkhead.
30. Carefully remove brake servo from the vehicle.
31. Unscrew nuts for brake master cylinder.
32. Remove heat shield, if fitted.
33. Carefully remove brake master cylinder from brake servo.
34. Remove adhesive residue from brake servo and plenum chamber bulkhead.
35. To do so, apply gentle heat from hot air blower to the adhesive residue, and pull it off.
36. Thoroughly clean surfaces.
37. Install in reverse order.
38. Connect brake pedal to brake servo .
39. After installing, bleed brake system and clutch.

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