Brake Pedal Assy: Service and Repair
Components, summary
WARNING: The travel of the brake pedal must not be shortened by additional floor coverings.
WARNING:
- Do not re-use fasteners that are worn or deformed in normal use.
- Some fasteners are designed to be used only once, and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts, washers, circlips and cotter pins. Always follow recommendations in this manual-replace these fasteners with new parts where indicated, and any other time it is deemed necessary by inspection.
1. Pedal bracket Removing and installing.
2. Screw
- 5 Nm (44 inch lbs.)
- Must engage in groove in pin -12-
- Do not tighten screw until locking clips -13- are installed
3. Seal
4. Screw
- 20 Nm (15 ft. lbs.)
5. Clutch master cylinder
6. Torsion spring
- Different for 4 and 6 cylinder engines
7. Clutch pedal
- Fixed in position by setting the clutch master cylinder
- Install on pin, item -12-
8. Pin
- Insert into clutch pedal and master cylinder
- Lock pin in pedal (arrow)
9. Brake pedal
- Install on pin, item -12-
10. Accelerator pedal
- Insert into pedal bracket
11. Accelerator pedal cable
- Cable detent ball must be engaged in accelerator pedal cable mount
12. Pin
13. Locking clip
- Always replace
- Qty: 2
- Install on pin, item -12-
14. Cable pulley with linkage
- TDI only
15. Hex nut
- Always replace
- 8 Nm (71 inch lbs.)
16. Washer
17. Bolt and washer assembly
- 25 Nm (18 ft. lbs.)
- Do not tighten in vehicle until after assembling brake servo unit
18. Vent valve
- For Cruise Control System (CCS)
- Adjusting. Refer to Cruise Control System (CCS) vent valve, adjusting.
19. Brake light switch
- Adjusting.
20. Clip
- Always replace
- Press into pedal bracket until fully seated
21. Stop block
- Markings determine correct installation position:
Manual transmission
- HS lettering is visible
- AG lettering faces in direction of travel
Automatic transmission
- AG lettering is visible
- HS lettering faces in direction of travel
22. Instrument panel cross member
23. Joint pin
- Install pedal bracket onto joint pin
24. Throttle Position Sensor (TPS)
- TDI only
25. Screw
- 8 Nm (71 inch lbs.)
Brake pedal, removing and installing
Removing and installing vacuum servo unit with brake master cylinder.
- Unbolt hydraulic line -1- for clutch master cylinder.
CAUTION: Before disconnecting the hydraulic line, protect the plenum chamber from brake fluid flowing out.
- Disconnect supply hose from elbow of master cylinder.
- Remove nut -1- at universal joint.
- Loosen eccentric by turning bolt (Torx(R) T50) clockwise, and remove bolt.
- Secure steering column with safety wire before removing steering column from steering gear pinion.
CAUTION:
- The splines between the top and bottom part of the steering column must not be separated during the removal and installation procedure.
- Turn the steering wheel into center position and do not alter position during repairs, otherwise the airbag spiral spring may be damaged
- Move universal joint down out of the way.
- Remove brake light switch -3- and CCS vent valves -2-.
- Remove hex socket-head bolt (arrow) for attaching pedal assembly to instrument panel member.
- Pull pedal assembly down and remove.
Note: Do not damage control module -1- for immobilizer (where applicable) when removing pedal assembly.
- To remove accelerator pedal, press catch in direction shown (arrows) while pressing out accelerator pedal.
Installing
CAUTION: Do not remove safety wire or other removal/installation aids from steering column until after the universal joint has been re-installed on the steering gear pinion.
- Install pedal assembly onto joint pin.
- Install hex socket-head bolt (arrow) for attaching pedal assembly to instrument panel member and tighten by hand.
Note: Do not tighten hex socket-head bolt (arrow) for attaching pedal assembly to instrument panel member until after installing the brake servo unit.
- Attach accelerator pedal (AP) cable.
- Install brake servo unit. Refer to Brake servo for brake master cylinder with 23.81 mm (0.937 inch) diameter piston, removing and installing.
After installing:
- Bleed brakes page. Refer to Brake hydraulic system, bleeding and changing brake fluid.
- Bleed clutch.
- Adjust brake light switch and CCS vent valves.
Brake light switch -F-, adjusting
- The pedal assembly must be bolted tight to the brake servo and to the instrument panel member before carrying out the adjustment.
The following adjustments should be carried out in case of complaint:
Pedal bracket for brake light switch with retaining clip
1. Brake light switch
2. Hex nut, M12 x 1.5
Part No. N 011 162 9
3. Spring washer, M12
Part No. N 012 232 3
4. Hex nut, M12 x 1.5
Part No. N 011 162 9
5. Brake pedal
CAUTION: Part numbers are listed here for reference only. Always check with your Parts department for the latest information.
- Pull brake light switch out of pedal bracket.
- Remove clip refer to item -20-.
- Turn nut -2- on brake light switch.
- Install brake light switch in pedal bracket, insert spring washer -3- and nut -4-.
- Adjust clearance -A-, then tighten nut -4-.
- Dimension -A- = 0.1 to 0.5 mm (0.004 to 0.020 inch)
- Tightening torque: 4 Nm (35 inch lbs.)
Pedal bracket with internal thread for brake light switch
1. Brake light switch
2. Hex nut, M12 x 1.5
Part No. N 011 020 8
3. Brake pedal
Note: Between the nut and the pedal bracket there is a spring clip (not shown), Part No. N 012 042 4.
CAUTION: Part numbers are listed here for reference only. Always check with your Parts department for the latest information.
- Install brake light switch in pedal bracket.
- Adjust clearance -A-, then tighten nut -2-.
- Dimension -A- = 0.1 to 0.5 mm (0.004 to 0.020 inch)
- Tightening torque: 4.5 Nm (39 inch lbs.)
Cruise Control System (CCS) vent valve, adjusting
- Insert vent valve into clip and push through to stop.
- Flush back valve by pulling back brake pedal or clutch pedal to stop.
Note: Only install the valve one time, otherwise an adequately tight fit cannot be assured.