Removing and installing brake servo, LHD vehicles with diesel engine — VW

🧭 Before you start

Fits: VW Jetta VI (16, 2010–2018)

• Opens: brake fluid, clutch fluid

Don't miss

• Insulation does not have to be removed completely.
• Threaded connections (2) do not have to be unscrewed.
• When assembling brake master cylinder with brake servo, make sure plunger rod is properly positioned in brake master cylinder.
• When joining brake master cylinder to brake servo, make sure seal is properly seated.
• Brake fluid must not be filled above MAX marking (1) to prevent brake fluid from running out.

📋 Procedure

1. Remove noise insulation General body repairs, exterior66Noise insulation; Assembly overview - noise insulation.
2. Remove engine cover 10Engine cover; Removing and installing engine cover.
3. If necessary, remove intake hose and air filter 23Air filter; Assembly overview - air filter housing.
4. Remove battery Electrical system27Battery; Assembly overview - battery.
5. Remove battery tray Electrical system27Battery; Assembly overview - battery.

6. If fitted, unscrew bolt (arrow).
7. Unclip intake hose (1) for preheater from retainer and remove it.
8. Remove bolt (arrow).
9. Move electrical wiring and hoses on left air pipe (1) to side using removal lever80 - 200.
10. Loosen hose clip (2) and remove air pipe (1).
11. Remove bolts (arrows).
12. Loosen hose clip (2) and remove air pipe (1).
13. Remove selector lever cable from ball head and cable support bracket 34Selector mechanism; Assembly overview - selector mechanism34Selector mechanism; Assembly overview - selector mechanism.
14. Remove selector lever from selector shaft on gearbox 34Selector mechanism; Assembly overview - selector mechanism.
15. Remove selector mechanism from gearbox 34Selector mechanism; Assembly overview - selector mechanism.
16. Place sufficient lint-free cloths in area of engine and gearbox.
17. Remove brake fluid reservoir .
18. Remove brake master cylinder .
19. Carefully take brake master cylinder out of brake servo.
20. Remove star fasteners (arrows).
21. Release electrical connector and pull off.
22. Unclip connector and wiring harness from bulkhead.
23. Fold insulation (1) for bulkhead forwards in (direction of arrow) and remove it carefully. [Note: Insulation does not have to be removed completely.]
24. Separate brake pedal from brake servo .
25. Unscrew threaded connections (1) from brake servo on pedal support. [Note: Threaded connections (2) do not have to be unscrewed.]
26. Carefully remove brake servo from the vehicle.
27. Carefully insert brake servo and tighten nuts hand-tight.
28. When assembling brake master cylinder with brake servo, make sure plunger rod is properly positioned in brake master cylinder.
29. When joining brake master cylinder to brake servo, make sure seal is properly seated.
30. Clip brake pedal to brake servo .
31. Tighten nuts (1) to (4) in the sequence shown.
32. Bleed brake system .
33. Bleed clutch 30Clutch mechanism; Bleeding clutch mechanism.
34. Insert locking lug of vacuum line (1) correctly into recess (arrow) of brake servo (2). [Note: Brake fluid must not be filled above MAX marking (1) to prevent brake fluid from running out.]

Other VW procedures

• Removing engine · 41 torque figures
• Removing and installing camshaft – VW Golf Cabriolet · 47 torque figures
• Adjusting valve timing – VW Passat B5 · 83 torque figures
• Removing and installing camshafts – VW Passat B6 · 39 torque figures
• Removing and installing coolant pump · 53 torque figures
• Renewing oil seal for right flange shaft – VW 2.0
• Checking oil level or changing oil in Haldex coupling – VW
• Removing and installing convertible roof actuation button E137 · 2 torque figures
• Removing and installing gearbox input speed sender G182 and oil temperature sender in multi-plate clutch G509 · 2 torque figures
• Removing and installing the fuel tank (CAYA, CAYB, CAYC)