Tandem Brake Servo / Brake Master Cylinder, Assembly Overview

Tandem brake servo / brake master cylinder, assembly overview

Note:
^ Brake master cylinders cannot be dismantled any further, i.e. no provision is made for servicing.
^ Use only fresh brake fluid. Refer to information on brake fluid reservoir.
^ Assignment of brake pipe connections, Refer to Hydraulic Control Assembly, Service and Repair, Hydraulic Unit and Brake Lines





1. -a-Vacuum hose
^ On gasoline engines the required vacuum is taken from the intake manifold.
^ 4-cylinder 1.6 ltr.. manual transmission
^ 4-cylinder 2.0 ltr.. manual transmission
^ 6-cylinder 2.5 ltr.. TDI
- Insert into brake servo unit

1. -b-Vacuum hose
^ On gasoline engines the required vacuum is taken from the intake manifold.
^ 4-cylinder 1.6 ltr.. automatic transmission
^ 4-cylinder 2.0 ltr.. automatic transmission
^ 6-cylinder 3.0 ltr.. automatic transmission
^ 6-cylinder 3.0 ltr.. manual transmission
- Insert into brake servo unit
2. Trunnion bolt, 10 Nm
^ Screw home
^ Unscrew to remove brake fluid reservoir
3. Brake fluid reservoir with float warning indicator
^ Functional test
- With the ignition switched on, remove the cap and press with your hand on the strainer that is visible. Warning lamp in instrument cluster lights and acoustic alarm sounds.
^ Removing and installing, Refer to Brake Master Cylinder With Brake Servo, Removing and Installing
^ Refer to label on reservoir before topping up brake fluid
4. Cap
5. Sealing plug
^ Moisten with brake fluid and insert into brake master cylinder
^ Press brake fluid reservoir into sealing plugs
6. Brake servo
^ Removing and installing, Refer to Brake Master Cylinder With Brake Servo, Removing and Installing
^ Adjust clevis A.
^ Functional test
- With the engine switched off, firmly depress the brake pedal several times (this reduces the vacuum present in the servo unit).
- Now depress brake pedal with moderate force, hold and start engine. If the servo unit is working properly, the pedal will be felt to give slightly under foot (servo assistance becomes effective).
^ If faulty renew complete.
7. Pedal bracket
8. Supply hose
^ Keep both ends closed off until it is installed.
^ Push on the hose as far as it will go.
9. Bulkhead
10. Bolt, 25 Nm
11. Flanged nut, 50 Nm
^ Always replace
12. Brake master cylinder
^ Cannot be repaired. If faulty, renew complete.
^ Has to be removed and installed together with the brake servo unit.
^ Removing and installing, Refer to Brake Master Cylinder With Brake Servo, Removing and Installing
13. Brake line, 15 Nm
^ Brake master cylinder/push rod piston circuit to hydraulic unit
^ Brake master cylinder/floating piston circuit to hydraulic unit
14. Sealing ring
^ Insert into groove at brake master cylinder
^ Replace after removing brake master cylinder