Removing and installing brake servo, RHD vehicles with petrol engine — VW

🧭 Before you start

Fits: VW Jetta VI (16, 2010–2018)

• Opens: brake fluid, clutch fluid

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• Make absolutely sure that the drive shafts can move freely in relation to the engine/gearbox support.In order to prevent damage, it must be ensured that the drive shafts do not rest on the engine/gearbox support!
• Release connector (1) for brake fluid level warning contact F34(2) and pull it off.
• Do not bend the brake lines!Do not interchange brake lines when connecting them.Mark installation position before removing brake lines. — Seal brake lines using sealing plugs from repair kit1H0 698 311 A.
• When assembling brake master cylinder with brake servo, make sure plunger rod is properly positioned in brake master cylinder.
• Ensure that brake servo (1) is correctly seated in recesses (arrows) of bulkhead (2).

📋 Procedure

1. Place sufficient lint-free cloths in area of engine and gearbox.
2. Draw off as much brake fluid as possible from brake fluid reservoir using brake filling and bleeding equipmentVAS 5234.
3. ⚠ Never allow brake fluid to come into contact with fluids that contain mineral oils (e.g. oil, petrol, cleaning agents). Mineral oils damage the plugs and seals in the brake system.Brake fluid is poisonous and must never be sucked out by mouth through a hose. Because of its caustic properties, it must also not come into contact with paintwork.Do not reuse drawn-off brake fluid.Always observe the relevant environmental regulations for disposal. — If fitted, remove dash panel trim (1) in driver footwell General body repairs, interior70Trims, interior; Overview of fitting locations - trims, interior.
4. To do this, unscrew bolts (arrows).
5. Release diagnostics connector (2) and pull it off.

6. Remove footwell vent on driver side Heating, air conditioning system80Air duct; Assembly overview - air duct and air distribution in passenger compartment.
7. If fitted, remove knee airbag General body repairs, interior69Knee airbags; Removing and installing knee airbag with igniter.
8. Separate brake pedal from brake servo .
9. Pull off engine cover upwards from fastening points (arrows)10Engine cover; Removing and installing engine cover.
10. Remove noise insulation and/or underride guard General body repairs, exterior66Noise insulation; Assembly overview - noise insulation.
11. Remove turbocharger 21Turbocharger; Removing and installing turbocharger.
12. Support engine in installation position 10 Assembly mountings; Supporting engine in installation position.
13. Release connectors and pull them all off simultaneously in (direction of arrow).
14. Lay wiring harness to one side.
15. Unbolt water pipe (1) at securing points (arrows).
16. Place water pipe (1) to one side.
17. Unscrew bolts (arrows) of engine/gearbox support on the engine.
18. Lower engine using spindles and pull towards front as far as possible. [Note: Make absolutely sure that the drive shafts can move freely in relation to the engine/gearbox support.In order to prevent damage, it must be ensured that the drive shafts do not rest on the engine/gearbox support!]
19. Release connector (2) on line (1) and pull it off.
20. Unclip line (1) from retainers (arrows) on intake manifold.
21. Disconnect line (1) at coupling point (3).
22. Pull water hose (2) off charge air cooler (1).
23. To do this, open clamp (arrow).
24. Unclip line (2) and water hoses (1) from retainers (arrows).
25. Lay line (2) and water hoses (1) to side.
26. Pull water hose (1) off coolant expansion tank (2).
27. To do this, open clamp (arrow).
28. Release and remove water hoses (arrows) from heat exchanger.
29. Place water hoses to one side.
30. Unbolt charge air cooler in sequence (1) through (6) as shown in illustration.
31. Pull charge air cooler (1) in (direction of arrow) out of intake manifold (2).
32. Pull out charge air cooler (1) up to bulkhead.
33. Release connector (1) for brake fluid level warning contact F34(2) and pull it off.
34. Separate connector (A) from brake light switchF and pull off.
35. Unscrew clamping washers (arrows) and fold insulating mat (1) forwards.
36. Pull return hose (2) for clutch sender cylinder (3) off brake fluid reservoir (4).
37. Seal return hose (2) for clutch master cylinder (3) with sealing tool T10249(1) or engine bung setVAS 6122.
38. Raise and tie return hose (2) in place.
39. Unscrew brake lines (3) from brake master cylinder (1).
40. ⚠ Do not bend the brake lines!Do not interchange brake lines when connecting them.Mark installation position before removing brake lines. — Seal brake lines using sealing plugs from repair kit1H0 698 311 A.
41. Unscrew nut (2).
42. Pull vacuum line (4) out of brake servo (1).
43. Remove heat shield (if installed).
44. Unscrew nut (1).
45. Carefully take brake master cylinder (2) out of brake servo.
46. Unclip brake lines (1) from retainer (2).
47. Unclip vacuum line (3) from retainer (2).
48. Unclip wiring harness (4) from bulkhead (arrow).
49. Remove bolt (1) from brake servo (2).
50. Carefully remove brake servo (2) from the vehicle.
51. Carefully remove brake servo from the vehicle.
52. Carefully insert brake servo and tighten bolts hand-tight.
53. When assembling brake master cylinder with brake servo, make sure plunger rod is properly positioned in brake master cylinder.
54. Ensure that brake servo (1) is correctly seated in recesses (arrows) of bulkhead (2).
55. When assembling brake master cylinder with brake servo, make sure seal is properly seated .
56. When installing charge air cooler (13), make sure seal (11) is properly seated.
57. Bolt on charge air cooler in sequence (1) through (6) as shown in illustration.
58. Tighten charge air cooler bolts in sequence (1) through (6) as shown in illustration.
59. Clip brake pedal to brake servo .
60. Bleed brake system .

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