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Home >> Audi >> 2004 >> A4 Cabriolet (8H7) L4-1.8L Turbo (AMB) >> Repair and Diagnosis >> Transmission and Drivetrain >> Clutch >> Clutch Hydraulic System >> Clutch Master Cylinder >> Service and Repair >> [012/01W/0A9] 5 Spd. M/T FWD

[012/01W/0A9] 5 Spd. M/T FWD


5 SPD. M/T 012/01W FWD

Master cylinder, removing and installing
Special tools, testers and auxiliary items required





^ 3094 Hose clip





^ VAG 1922 Pliers

Removing
- Remove rubber seal from plenum chamber in direction of arrow.





- Remove cover -1-over plenum chamber.
- Check whether an encoded radio is installed. If so, obtain anti-theft code.

CAUTION: On vehicles equipped with Audi Telematics by OnStar(R) switch-off the emergency (back-up) battery for the Telematic/Telephone Control Module prior to disconnecting the vehicle battery. Switch-on the emergency (back-up) battery after reconnecting the vehicle battery

- Disconnect battery ground strap with ignition switched off.





- Use screwdriver to pry off the two caps -3-.
- Remove nuts -4- and detach the two wiper arms -2-.
- Pull off clips -1- and remove cowl panel grille -5-.

Remove electronics box in plenum chamber as follows:





- Screw out bolts -arrows- and pull off sealing cover.





- Carefully pry off retainer bar with screwdriver -arrow-.





- Release connector latches -arrows- and pull off connectors -1- and -2- on engine control module.





- Pull off connector -2- from connector rail.
- Disconnect wire -1-.





- Release catches -arrows- and pull auxiliary relay carrier in electronics box upward to remove.
- Pull engine wiring harness together with rubber grommet out of recess in electronics box.





- Remove nuts -arrows- and lift out electronics box -1-.

Note:
^ Make sure that brake fluid does not escape into the plenum chamber or onto the transmission below. If this does happen, clean the affected areas thoroughly.
^ Protect the carpet from brake fluid using rags when performing work in the footwell.





- Clamp supply hose -A- leading to brake fluid reservoir using special tool 3094. Pull hose off at master cylinder and plug it.
- Remove rubber grommet from bulkhead on the supply hose connecting line.
- Use a screwdriver to pry out retaining clip -C- and then pull out line -13slightly.





- Remove bolt from brake fluid reservoir -1- and disconnect connector from fluid level below.

Note: Do not remove the brake fluid reservoir.

Note:
^ For ease of illustration, brake fluid reservoir is not shown.
^ To remove the top Torx bolt, swivel brake fluid reservoir slightly to one side.





- Remove the two Torx bolts -arrows-.
- Remove vacuum line from brake servo -1-
- Remove driver's side storage compartment.





- Detach brake pedal from brake servo.
- Disconnect steering column from steering gear -arrow A-.





- Disconnect connector on clutch pedal switch -1-, brake pedal switch -2and on accelerator pedal module -3-.
- Remove securing bolt from mounting bracket -arrow B- and complete pedal cluster.

Release master cylinder operating rod from clutch pedal as follows:
- Removing over-center spring

Note:
^ Make sure a tight connection in the clutch pedal switch Pos. 6 as well as the Clutch Pedal Position (CPP) Switch -F194- Pos. 14 in the pedal cluster, these switches may only be installed once.





^ When releasing clutch pedal make sure that it does not strike against retainer for clutch pedal switch --arrow--. This could break the retainer.

- Insert pliers VAG 1922 into recess of clutch pedal, press retainer together -arrows- and detach clutch pedal from master cylinder.





- Remove retaining clip -1- and pull off clutch pedal -2-.
- Remove bolts -3- and detach master cylinder -4-.

Installing
Install in reverse order, paying attention to the following:





- Insert master cylinder and tighten screws -3- to 20 Nm.





- Insert retainer -1-into clutch pedal.
- Press clutch pedal in direction of arrow to engage, make sure that retainer -1- is correctly locked in clutch pedal.
- Install over-center spring.

A second mechanic is required for the next step.





- Insert complete pedal cluster and install bolt -1- hand-tight. The second mechanic must simultaneously insert line into master cylinder from plenum chamber side.





- Tighten bolts for brake servo -arrows- to 25 Nm.





- Press in retaining clip -C- up to stop.
- Insert line -13- into master cylinder until it is heard to engage.
- Insert rubber grommet -D- over supply hose connecting line -A- into bulkhead.
- Slide supply hose -A- for the brake fluid reservoir up to stop.
- Remove special tool 3094.
- Install bolt for brake fluid reservoir.





- Tighten hex socket-head bolt -arrow B- for securing pedal cluster on instrument panel support to 25 Nm.
- Plug in connectors -1-, -2- and -3-.
- Connect brake pedal to brake servo.
- Secure steering column to steering gear -arrow A-.
- Installing driver's storage compartment:
- Bleed clutch system.





- Insert electronics box and tighten nuts -arrows- to 4 Nm.
- Route engine wiring harness and connect connectors to connector point.
- Install engine control module and if applicable auxiliary relay carrier with auxiliary fuse carrier.
- Press on sealing cover hand-tight and tighten screws in diagonal sequence to 4 Nm.

Note: On re-connecting battery, remember to check and re-activate vehicle equipment (radio, clock, convenience electric, etc.).


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