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-

⇒ Item 15 (page 107)

 .

– Make sure the sealing plugs are seated correctly in the brake

master cylinder -item 10- 

⇒ Item 10 (page 107)

 .

– Coat the plugs with brake fluid before pushing the brake fluid

reservoir into the master brake cylinder -item 10-

⇒ Item 10 (page 107)

 .

– 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

106

♦ 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 .