Volkswagen ID.3: Brakes, hydraulics, regulator, servo. Brake servo and brake master cylinder

• Assembly overview – brake servo/brake master cylinder, left-hand drive vehicles
• Assembly overview – brake servo/brake master cylinder, right-hand drive vehicles
• Removing and installing brake master cylinder
• Removing and installing brake servo [NX6], left-hand drive vehicles
• Removing and installing brake servo [NX6], right-hand drive vehicles

Assembly overview – brake servo/brake master cylinder, left-hand drive vehicles

Assembly overview – brake servo/brake master cylinder, left-hand drive vehicles

1 - Brake line

❏ Brake master cylinder/secondary piston circuit to hydraulic unit

❏ M12 x 1

❏ With standard tool: 14 Nm

❏ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm

2 - Brake line

❏ Brake master cylinder/primary piston circuit to hydraulic unit

❏ M12 x 1

❏ With standard tool: 14 Nm

❏ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm

3 - Brake fluid level warning contact -F34-

4 - Cap

5 - Brake fluid reservoir

6 - Bolt

❏ 4 Nm

7 - Brake servo -NX6-

❏ With brake servo control unit -J539-

❏ With brake pedal position sender -G100-

❏ With brake pedal position sender 2 -G836-

❏ → Rep. gr.47; Removing and installing brake servo

8 - Gasket for brake servo

❏ Renew after removing

9 - Nut

❏ Qty. 2

❏ Renew after removing

❏ 20 Nm

10 - Mounting bracket with brake pedal

❏ → Rep. gr.46; Assembly overview – brake pedal

❏ → Rep. gr.46; Removing and installing mounting bracket

11 - Seal

❏ Renew after removing

12 - Brake master cylinder

❏ → Chapter „Removing and installing brake master cylinder“

13 - Bolt

❏ Qty. 2

❏ Renew after removing

❏ M8 x 31

❏ 30 Nm

14 - Plug

Assembly overview – brake servo/brake master cylinder, right-hand drive vehicles

Assembly overview – brake servo/brake master cylinder, right-hand drive vehicles

1 - Cap

2 - Brake fluid reservoir

3 - Stud

❏ 4 Nm

4 - Brake servo -NX6-

❏ With brake servo control unit -J539-

❏ With brake pedal position sender -G100-

❏ With brake pedal position sender 2 -G836-

❏ → Rep. gr.47; Removing and installing brake servo

5 - Gasket for brake servo

❏ Renew after removing

6 - Mounting bracket with brake pedal

❏ → Rep. gr.46; Assembly overview – brake pedal

❏ → Rep. gr.46; Removing and installing mounting bracket

7 - Nut

❏ Qty. 2

❏ Renew after removing

❏ 20 Nm

8 - Seal

❏ Renew after removing

9 - Brake master cylinder

❏ → Chapter „Removing and installing brake master cylinder“

10 - Bolt

❏ Renew after removing

❏ M8 x 31

❏ 30 Nm

11 - Brake line

❏ Brake master cylinder/secondary piston circuit to hydraulic unit

❏ M12 x 1

❏ With standard tool: 14 Nm

❏ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm

12 - Brake line

❏ Brake master cylinder/primary piston circuit to hydraulic unit

❏ M12 x 1

❏ With standard tool: 14 Nm

❏ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm

13 - Bolt

❏ Renew after removing

❏ M8 x 31

❏ 30 Nm

14 - Plug

15 - Brake fluid level warning contact -F34-

Removing and installing brake master cylinder

Removing and installing brake master cylinder

Special tools and workshop equipment required

♦ Brake filling and bleeding equipment -VAS 6860-

♦ Engine bung set -VAS 6122-

♦ Socket/bit set, 39-piece -VAS 6928-

Removal and installation are described for a left-hand drive vehicle as an example.

Removing

Vehicles with vibration isolation strut

– Remove vibration isolation strut → General body repairs, exterior; Rep. gr.50; Lock carrier; Removing and installing vibration isolation strut.

All vehicles (continued)

Left-hand drive vehicles

– Remove battery tray → Electrical system; Rep. gr.27; Battery; Removing and installing battery tray.

All vehicles (continued)

Right-hand drive vehicles

– Remove coolant expansion tank and lay aside with coolant hoses still attached → Electric rear-wheel drive EIP220 and all-wheel drive EIA200, EIP220; Rep. gr.19; Cooling system/coolant; Removing and installing coolant expansion tank.

All vehicles (continued)

– Extract as much brake fluid as possible from brake fluid reservoir -1- using brake filling and bleeding equipment -VAS 6860- -A-.

NOTICE

Risk of damage due to corrosion.

– Make sure that no brake fluid gets onto electrical contacts.

– Place sufficient lint-free cleaning cloths in area of brake servo.

– Mark and unscrew brake lines -2- and -3- from brake master cylinder.

– Seal threaded holes in brake master cylinder immediately with M12 sealing plugs (assembly parts).

– Seal brake lines with engine bung set -VAS 6122-.

Note

Fit dust caps from bleeder screws on brake lines as an alternative.

– Disconnect electrical connector -2-.

– Unscrew bolts -4- using socket from Socket set, 39 piece -VAS 6928-.

– Pull out brake master cylinder -3-.

Installing

Install in reverse order of removal, observing the following:

– Make sure that seal and push rod are seated correctly.

– → Rep. gr.47; Bleed hydraulic system.

– Carry out function “Basic setting brake servo” using → Vehicle diagnostic tester → Rep. gr.00; Access to diagnoses.

Tightening torques

♦ → Rep. gr.47; Assembly overview – brake servo/brake master cylinder

Removing and installing brake servo [NX6], left-hand drive vehicles

Removing and installing brake servo [NX6], left-hand drive vehicles

Special tools and workshop equipment required

♦ Brake filling and bleeding equipment -VAS 6860-

♦ Engine bung set -VAS 6122-

♦ Hot air blower -VAS 1978/14A-

♦ Open ring spanner insert, AF 11mm -V.A.G 1410/6-

♦ Socket/bit set, 39-piece -VAS 6928-

♦ Torque wrench -VAS 6854-

♦ Universal joint -V.A.G 1410/7-

♦ assembly tool -V.A.G 1410/8-

Brake servo -NX6- is referred to hereafter as brake servo.

For sealing plugs (assembly parts), see electronic parts catalogue (ETKA)

1 - Plugs M10

2 - Plugs M12

Removing

If the brake servo control unit -J539- is renewed, perform the test plan for renewal of the control unit:

– Carry out function “Renew control unit” using → Vehicle diagnostic tester → Rep. gr.00; Access to diagnoses.

Continued

– Remove air intake unit of heater and air conditioning unit → Heating, air conditioning system; Rep. gr.87; Front heater and air conditioning unit; Removing and installing air intake unit of heater and air conditioning unit.

– Remove battery tray → Electrical system; Rep. gr.27; Battery; Removing and installing battery tray.

– Extract as much brake fluid as possible from brake fluid reservoir -1- using brake filling and bleeding equipment -VAS 6860- -A-.

– Disconnect electrical connector -2- from brake fluid level warning contact -F34- and electrical connector -3- from brake servo -1-.

NOTICE

Risk of damage due to corrosion.

– Make sure that no brake fluid gets onto electrical contacts.

– Place sufficient lint-free cleaning cloths in area of brake servo.

– Mark and unscrew brake lines -2- and -3- from brake master cylinder.

– Seal threaded holes in brake master cylinder immediately with M12 sealing plugs (assembly parts).

– Seal brake lines with engine bung set -VAS 6122-.

Note

Fit dust caps from bleeder screws on brake lines as an alternative.

– → Rep. gr.46; Separating brake pedal from and joining to brake servo.

– Unscrew nuts -3- and -4- for brake servo from mounting bracket.

NOTICE

Risk of damage to the plenum chamber bulkhead due to improper separation of the bonded joint.

– Never lever the brake servo off the plenum chamber bulkhead to separate the bonded joint.

– If brake servo gets jammed in holes, loosen nuts -1- and -2- on mounting bracket.

– Pull brake servo off bulkhead, and remove it from vehicle.

Important

● Make sure that the brake lines from brake master cylinder are not bent.

– Remove adhesive residue -arrows- from brake servo -2- and from bulkhead -1-.

– To do so, apply gentle heat from hot air blower -VAS 1978/14A- to the adhesive residue and pull it off.

– Thoroughly clean surfaces.

Installing

Install in reverse order of removal, observing the following:

– Renew gasket between brake servo and bulkhead.

– Insert brake servo, and screw on nuts by hand.

– → Rep. gr.46; Separating brake pedal from and joining to brake servo.

– Use assembly tool -V.A.G 1410/8- to fit brake lines.

Important

● Keep brake lines straight when fitting them.

– Tighten brake servo.

– → Rep. gr.47; Bleed hydraulic system.

If the brake servo control unit -J539- has been renewed, conclude the test plan for renewal of the control unit:

– Conclude function “Renew control unit” using → Vehicle diagnostic tester → Rep. gr.00; Access to diagnoses.

Continued

Tightening torques

Assembling special tools for tightening brake lines

1 - Torque wrench -VAS 6854-

2 - Universal joint -V.A.G 1410/7-

3 - Open ring spanner insert AF 11 -V.A.G 1410/6-

♦ → Rep. gr.47; Assembly overview – brake servo/brake master cylinder, left-hand drive vehicles

♦ → Electrical system; Rep. gr.27; Battery; Assembly overview – battery

♦ → Heater and air conditioning unit; Rep. gr.87; Front heater and air conditioning unit; Assembly overview – air intake unit of heater and air conditioning unit

Removing and installing brake servo [NX6], right-hand drive vehicles

Removing and installing brake servo [NX6], right-hand drive vehicles

Special tools and workshop equipment required

♦ Brake filling and bleeding equipment -VAS 6860-

♦ Engine bung set -VAS 6122-

♦ Hot air blower -VAS 1978/14A-

♦ Open ring spanner insert, AF 11mm -V.A.G 1410/6-

♦ Socket/bit set, 39-piece -VAS 6928-

♦ Torque wrench -VAS 6854-

♦ Universal joint -V.A.G 1410/7-

♦ assembly tool -V.A.G 1410/8-

Brake servo -NX6- is referred to hereafter as brake servo.

For sealing plugs (assembly parts), see electronic parts catalogue (ETKA)

1 - Plugs M10

2 - Plugs M12

Removing

If the brake servo control unit -J539- is renewed, perform the test plan for renewal of the control unit:

– Carry out function “Renew control unit” using → Vehicle diagnostic tester → Rep. gr.00; Access to diagnoses.

Continued

– Remove air intake unit of heater and air conditioning unit → Heating, air conditioning system; Rep. gr.87; Front heater and air conditioning unit; Removing and installing air intake unit of heater and air conditioning unit.

For vehicles with heat pump valve unit

– Remove heat pump valve unit → Heating, air conditioning; Rep. gr.87; Heat pump valve unit; Removing and installing heat pump valve unit.

All vehicles (continued)

– Extract as much brake fluid as possible from brake fluid reservoir -1- using brake filling and bleeding equipment -VAS 6860-.

– Disconnect electrical connector -2- from brake fluid level warning contact -F34- of brake fluid reservoir -1-.

– Remove stud -2-.

– Pull brake fluid reservoir -1- upwards out of brake master cylinder.

NOTICE

Risk of damage due to corrosion.

– Make sure that no brake fluid gets onto electrical contacts.

– Place sufficient lint-free cleaning cloths in area of brake servo.

– Unscrew brake lines -2- and -3- from brake master cylinder -1-.

– Seal threaded holes in brake master cylinder immediately with M12 sealing plugs (assembly parts).

– Seal brake lines with engine bung set -VAS 6122-.

Note

Fit dust caps from bleeder screws on brake lines as an alternative.

– → Rep. gr.46; Separating brake pedal from and joining to brake servo.

– Unscrew nuts -3- and -4- for brake servo from mounting bracket.

NOTICE

Risk of damage to the plenum chamber bulkhead due to improper separation of the bonded joint.

– Never lever the brake servo off the plenum chamber bulkhead to separate the bonded joint.

– If brake servo gets jammed in holes, loosen nuts -1- and -2- on mounting bracket.

– Disconnect electrical connector -1- from brake servo -2-.

– Remove brake servo from vehicle.

Important

● Make sure that the brake lines from brake master cylinder are not bent.

– Remove adhesive residue -arrows- from brake servo -2- and from bulkhead -1-.

– To do so, apply gentle heat from hot air blower -VAS 1978/14A- to the adhesive residue and pull it off.

– Thoroughly clean surfaces.

Installing

Install in reverse order of removal, observing the following:

– Renew gasket between brake servo and bulkhead.

– Insert brake servo, and screw on nuts by hand.

– → Rep. gr.46; Separating brake pedal from and joining to brake servo.

– Use assembly tool -V.A.G 1410/8- to fit brake lines.

Important

● Keep brake lines straight when fitting them.

– Tighten brake servo.

– → Rep. gr.47; Bleed hydraulic system.

If the brake servo control unit -J539- has been renewed, conclude the test plan for renewal of the control unit:

– Conclude function “Renew control unit” using → Vehicle diagnostic tester → Rep. gr.00; Access to diagnoses.

Continued

Tightening torques

Assembling special tools for tightening brake lines

1 - Torque wrench -VAS 6854-

2 - Universal joint -V.A.G 1410/7-

3 - Open ring spanner insert AF 11 -V.A.G 1410/6-

♦ → Rep. gr.47; Assembly overview – brake servo/brake master cylinder, right-hand drive vehicles

Brake, brake mechanics. Brake pedalBrakes, hydraulics, regulator, servo. Hydraulic system