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VW Passat 1.9 TDi 2001 - Servo and master cylinder replacement #

Posted by Paul Howd on September 12, 2011, 6:29 pm

Year of Manufacture *: Y reg

Hi

Just had a phone call asking how much to change. Not done one before but seem to recall reading that these can be a bit of a PITA.

Any helpful hints on technique or how long job should take?

(Or should I run away! )

I have not seen the car yet.

Re: VW Passat diesel 1.9TDI-servo and master cylinder replacement

Posted by Jon Morgan <iframe src='https://members4.boardhost.com/ukautotalk/info/user=ukat3190' width='330' height='300' border=0 style='border:none;'> on September 13, 2011, 1:23 pm, in reply to "VW Passat diesel 1.9TDI-servo and master cylinder replacement"

Quote 1/2 a day to be sure.
Not too bad to do. depends on the servo fitted as to how easily it squeezes out of the hole it's in.

There is a 10" single diaphragm or 7 1/2" twin diaphragm unit - I can't remember off hand which is the tighter fit, but it's no major hassle whichever is fitted.

It may be an idea to remove the drain bung underneath while you're in there - these block, fill the scuttle & servo with water & are the usual reason for servo failure.

Jon

Re: VW Passat diesel 1.9TDI-servo and master cylinder replacement

Posted by Luke Browne <iframe src='https://members4.boardhost.com/ukautotalk/info/user=UKAT1817' width='330' height='300' border=0 style='border:none;'> on September 15, 2011, 11:15 pm, in reply to "Re: VW Passat diesel 1.9TDI-servo and master cylinder replacement"
Luke Browne

Theres also a second bung under the battery which is worth cleaning, the battery and tray have to be removed.
Done a few of these, be careful when fitting the master cylinder as the servo shaft can go in at an angle because of the tight fitting, causes a very stiff pedal.

Re: VW Passat diesel 1.9TDI-servo and master cylinder replacement

Posted by Jon Morgan <iframe src='https://members4.boardhost.com/ukautotalk/info/user=ukat3190' width='330' height='300' border=0 style='border:none;'> on September 15, 2011, 11:53 pm, in reply to "Re: VW Passat diesel 1.9TDI-servo and master cylinder replacement"
Jonathan Morgan

Hi Luke,
the battery bung can be accessed from under the car by removing the undertray & removing the troublesome leaf collecting device for good with long nose pliers.
Or you can have a rummage around via the N/S wheelarch - send the car up half way on the ramp & look through to the underside of the plenum & you will see the bung hanging down, this is particularly useful on a V6 Audi where the bung is inaccesible from under the car.
The interesting thing is, the bung cleaning was a serviceable item on pre 2001 vehicles, but not on post 2001 vehicles - the bung didn't change & was just as prone to blocking with leaf matter as the earlier model - weird how VAG's policy dept. works, maybe they just fancied selling more servo's & convenience modules on the later models??

Jon.

Re: VW Passat diesel 1.9TDI-servo and master cylinder replacement

Posted by con morrin <iframe src='https://members4.boardhost.com/ukautotalk/info/user=ukat3018' width='330' height='300' border=0 style='border:none;'> on September 19, 2011, 11:33 pm, in reply to "Re: VW Passat diesel 1.9TDI-servo and master cylinder replacement"
Conleth Morrin

we had passat 03 with water leaking into engine oil and it was due to the drain plug under the battery was blocked and the vacumn pump on engine was drawing water through the servo and into engine oil.

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