[01A] 5 Spd. M/T AWD

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





^ 3094 Hose clamp





^ VAG 1922 Pliers

Removing
- Pull off gasket on plenum chamber in direction of arrow.





- Remove cover -1- on top of plenum chamber.
- First check if a coded radio is installed. In this case obtain anti-theft code.
See Caution for disconnecting Telematics battery
- Disconnect battery Ground strap with ignition switched off.





- Pry off two covers -3- with a screwdriver.
- Remove nuts -4- and two wiper arms -2-.
- Pull off clips -1- and remove cowl panel grille -5-.

Remove electronics box in plenum chamber as follows:





- Remove bolts -arrows- and take off cover lid.





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





- Loosen connector locks -arrows- and unplug connectors -1- and -2- from engine control module.





- Unplug connectors -2- from connector strip.
- Unscrew electrical wire connection -1-.





- Release locks -arrows- and pull auxiliary relay carrier in electronics box upward and off.
- Pull engine wiring harness together with grommet out of recess in electronics box.





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

Note:
^ During the following steps make sure that brake fluid does not escape into plenum chamber or onto transmission below. If it does, clean affected area thoroughly.
^ When working in footwell, cover carpet with cloths to protect it from brake fluid spillage.





- Disconnect supply hose -A- to brake fluid reservoir with special tool 3094, detach from master cylinder and seal with plug.
- On bulkhead remove grommet above connecting tube for supply hose.
- Pry out securing clip -C- with screwdriver and then pull tube -B- out slightly.





- Remove bolt for brake fluid reservoir -1- and unplug connector for monitoring fluid level by pulling downward.

Note: Do not remove brake fluid reservoir.

Note:
^ Brake fluid reservoir not shown for purpose of clearer illustration.
^ To remove the top TORX bolt, swivel brake fluid reservoir sideways slightly.





- Remove two TORX bolts -arrows-.
- Remove vacuum tube to brake booster -1-
- Remove driver's storage compartment.





- Separate brake pedal from brake booster.





- Separate steering column from steering box -arrow A-.
- Unplug connectors from clutch pedal switch -1-, brake pedal switch -2and accelerator pedal module -3-.
- Remove bolt for mounting bracket -arrow B- and remove pedal cluster assembly.

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

Note:





^ When releasing make sure clutch pedal does not bounce against clutch pedal switch mount -arrow, Otherwise the mount might break.
^ In order to assure sufficiently secure fitting of clutch pedal switch Item 6 as well as Clutch Pedal Position (CPP) Switch F194- Item 14 in pedal cluster, these switches must not be installed more than once.

- Insert pliers VAG 1922 into recesses in clutch pedal, compress mount arrows and separate clutch pedal from master cylinder.





- Remove securing clip -1- and clutch pedal -2-.
- Remove bolts -3- and master cylinder -4-.

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





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





- Insert mount -1- in clutch pedal.
- Push clutch pedal in direction of arrow to lock into place, while making sure mount -1- is properly secured in clutch pedal.
- Installing over-center spring.

For the next step a second technician is required.





- Insert pedal cluster assembly and tighten bolt -1- hand-tight. Simultaneously, second technician feeds tube from plenum chamber side into master cylinder.





- Tighten brake booster bolts -arrows- to 25 Nm.





- Push in securing clip -C- as far as it will go.
- Insert tube -B- in master cylinder until it clicks into position.
- Install grommet -D- over connecting tube/supply hose -A- and into bulkhead.
- Push on supply hose -A- to brake fluid reservoir as far as it will go.
- Remove special tool 3094.
- Screw in brake fluid reservoir bolt.





- Tighten hex socket-head bolt -arrow B- which secures pedal cluster to instrument panel carrier to 25 Nm.
- Attach connectors -1-, -2- and -3-.
- Connect brake pedal to brake booster.
- Attach steering column to steering box -arrow A-.
- Install driver's storage compartment:
- Bleed clutch system .





- Insert electronics box and tighten nuts -arrows- to 4 Nm.
- Route engine wiring harness and attach connection in connector station.
- Install engine control module plus auxiliary relay carrier and auxiliary fuse holder, if installed.
- Push on cover lid by hand and tighten bolts diagonally - 4 Nm.
See Caution for connecting Telematics battery

If the battery is reconnected remember to check and activate vehicle equipment (radio, clock, convenience electric etc.).