VW Passat & Audi A4 1990-2000

Vacuum Servo

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REMOVAL & INSTALLATION
Under-Dash Mounted Servo/Throttle Control Element
  1. On models with the servo/throttle control element attached directly to the accelerator pedal, remove the left air duct and/or footwell ducts as necessary to access the unit.
  2.  
  3. Disconnect the vacuum line from the servo.
  4.  
  5. Carefully release the rod from the pedal assembly using a suitable prytool.
  6.  
  7. Remove the mounting bracket fasteners and remove the servo unit.
  8.  



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Fig. The accelerator pedal mounted servo unit and related components. 1. Vacuum hose-2. Clutch pedal vent valve-3. Brake pedal vent valve-4. Servo unit



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Fig. 1. Servo unit-2. Mounting bracket-3. Pedal cluster assembly-4. Mounting ball



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Fig. The servo unit and related components. 1. Servo unit-2. Adjustment sleeve-3. Accelerator cable

To install :

  1. Installation is in reverse order of removal noting the following:
  2.  
  3. Once the servo is installed, check and adjust the throttle cable as necessary.
  4.  
  5. Adjust the servo unit by turning the adjusting sleeve about 1 / 8 turn counterclockwise to unlock it and pulling the sleeve rearward until all play is eliminated.
  6.  
  7. Lock the sleeve in place by turning it clockwise.
  8.  

Engine Mounted Servo/Throttle Control Element
  1. Disconnect the servo throttle link rod ball socket from the throttle linkage.
  2.  
  3. Disconnect the vacuum line from the servo.
  4.  
  5. Remove the mounting fastener(s) and remove the actuator from the engine.
  6.  
  7. Installation is the reverse of removal.
  8.  



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Fig. To release the rod from the throttle assembly, remove the retaining clip and carefully remove the ball socket



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Fig. The servo unit location on the 1.8L engine. The intercooler-to-intake manifold hose has been removed for accessibility and photography purposes

 
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