Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 795
– Disconnect the bat‐
tery. Refer to ⇒ Elec‐
trical Equipment;
Rep. Gr. 27 ; Battery;
Battery, Disconnect‐
ing and Connecting .
– Remove the battery.
Refer to ⇒ Electrical
Equipment; Rep. Gr.
27 ; Battery; Battery,
Removing and Instal‐
ling .
– Remove the engine
cover. Refer to ⇒ En‐
gine Mechanical,
Fuel Injection and Ig‐
nition; Rep. Gr. 10 ;
Engine Cover; En‐
gine Cover, Remov‐
ing and Installing .
Diesel Vehicles
– Unclip the vacuum line from the air guide hose.
– Open the clamps -1 and 2-.
– Remove the air guide hose.
– Remove the air filter housing. Refer to ⇒ Engine Mechanical,
Fuel Injection and Glow Plug; Rep. Gr. 23 ; Air Filter; Air Filter
Housing, Removing and Installing .
Vehicles with 2.0 L Gasoline Engine
– Open the clamps -2 and 3-.
– Remove the air guide hose -1-.
– Remove the air filter housing. Refer to ⇒ Engine Mechanical,
Fuel Injection and Ignition; Rep. Gr. 24 ; Air Filter; Air Filter
Housing, Removing and Installing .
Continuation for All Vehicles
– Remove the battery holder. Refer to ⇒ Electrical Equipment;
Rep. Gr. 27 ; Battery; Battery Tray, Removing and Installing .
– Place sufficient lint-free cloths in the area of the engine and
transmission.
– Extract as much brake fluid as possible from the brake fluid
reservoir with the Brake Charger/Bleeder Unit - VAS5234- .
Vehicles with a Manual Transmission
– Remove the supply hose -2- for the clutch master cylinder
-3- from the brake fluid reservoir -4-.
– Seal the supply hose -2- for the clutch master cylinder -3- using
Sealing Tool - T10249- -1- or Engine Bung Set - VAS6122- .
– Tie up the return hose -2-.
Continuation for All Vehicles
– If equipped release the connector -2- from the Vacuum Sensor
- G608- .
– Release and remove the connector -3- from the Brake Fluid
Level Warning Switch - F34- .
– Release the connector -1- from the Brake Lamp Switch - F-
and remove.
– Remove the bolt -1- and pull the brake fluid reservoir -2- from
the sealing plugs.
– Remove the brake lines -1- on brake master cylinder.
– Close the brake line with Sealing Plugs from the Repair Kit -
1H0 698 311 A- .
– Close the open connections on the brake master cylinder with
a suitable plug from the Engine Bung Set - VAS6122- .
– Remove the nuts -2- from the brake master cylinder.
– Remove the heat shield, if equipped.
– Carefully take brake master cylinder out of brake booster.
– Remove the Brake Light Switch - F- from brake master cylin‐
der.
Installing
Install in reverse order of removal. Note the following:
– When installing together the brake master cylinder and brake
booster, make sure that the push rod is correctly located in the
brake master cylinder.
– Make sure the seal fits correctly when attaching the master
brake cylinder to the brake booster -item 15-
.
– Make sure the sealing plugs are seated correctly in the brake
master cylinder -item 10-
.
– Coat the plugs with brake fluid before pushing the brake fluid
reservoir into the master brake cylinder -item 10-
.
– Bleed the brake system. Refer to
⇒ “6.2 Hydraulic System, Standard Bleeding”, page 132
Vehicles with Manual Transmission
– The seals -2- must be located in the return hose -1- to the
clutch master cylinder.
– Bleed the clutch mechanism. Refer to ⇒ Manual Transmis‐
sion; Rep. Gr. 30 ; Clutch Mechanism; Clutch Mechanism,
Bleeding .
Tightening Specification
♦ Refer to
⇒ “3.1 Overview - Brake Booster/Brake Master Cylinder”, page
♦ Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition;
Rep. Gr. 10 ; Engine Cover; Engine Cover, Removing and
Installing .
♦ Refer to ⇒ Engine Mechanical, Fuel Injection and Glow Plug;
Rep. Gr. 23 ; Air Filter; Overview - Air Filter Housing .
♦ Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition;
Rep. Gr. 24 ; Air Filter; Overview - Air Filter Housing .
♦ Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Over‐
view - Battery .
3.4
Brake Booster, Removing and Installing
Special tools and workshop equipment required
♦ Sealing Tool - T10249-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Torque Wrench 1331 Insert - Ring Wrench - 11mm & 17mm -
VAG1331/2-
♦ Torque Wrench 1410 - VAG1410-
♦ Hot air gun for example Wiring Harness Repair Set - Hot Air
Blower - VAS1978/14A- .
♦ Brake Charger/Bleeder Unit - VAS5234-
♦ Engine Bung Set - VAS6122-
♦ Adhesive Strip Remover - VAS6349-
♦ Sealing Plugs from the Repair Kit - 1H0 698 311 A-
♦ Drill for example cordless drill or straight sander.
Note
First check the brake booster vacuum system in case of com‐
plaints regarding the brake booster.
⇒ “4.4 Vacuum System, Checking”, page 123
Component Location
1 - ABS Hydraulic Unit - N55- and ABS Control Module - J104-
2 - Brake Booster
Removing
– If the vehicle has a coded radio, get the radio code from the
customer before beginning.
– Disconnect the battery. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27 ; Battery; Battery, Disconnecting and Connecting .
– Remove the battery. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27 ; Battery; Battery, Removing and Installing .
– Remove the engine cover. Refer to ⇒ Engine Mechanical,
Fuel Injection and Ignition; Rep. Gr. 10 ; Engine Cover; Engine
Cover, Removing and Installing .
Diesel Vehicles
– Unclip the vacuum line from the air guide hose.
– Open the clamps -1 and 2-.
– Remove the air guide hose.
– Remove the air filter housing. Refer to ⇒ Engine Mechanical,
Fuel Injection and Glow Plug; Rep. Gr. 23 ; Air Filter; Air Filter
Housing, Removing and Installing .
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