[01E] 6 Spd. M/T AWD
Master cylinder, removing and installing
Special tools, testers and auxiliary items
^ Hose clamp 3094
Removing
- If installed, remove cover above plenum chamber.
- Disconnect battery Ground (GND) strap with the ignition switched off.
- Remove E-Box from plenum chamber as follows:
- Pull off clip -1- and lift wind grill -A- slightly. Now remove screw (arrow -2-).
- Remove remaining screws (arrows) and remove cover.
- Remove engine control unit and 8-point relay carrier (if fitted)
- Unplug connector in connector station.
- Pull engine wiring harness together with rubber grommet out through opening in electronics box.
- Unscrew both nuts -A-.
- Lift E-box off studs at the rear and then pull it out of securing point -B-.
Note:
^ In the following procedures, make sure that no brake fluid escapes into the plenum chamber or onto the transmission below. If this does happen, clean the affected areas thoroughly.
^ When performing work in the footwell, put cloths on the carpet to protect it from possible brake fluid spills.
- Clamp supply hose -A- from brake fluid reservoir using special tool 3094. Pull hose off master cylinder and plug hose.
- Remove rubber grommet for compensation hose above connecting line from transverse wall.
- Pry out retaining clip -C- using a screwdriver and pull line -B- out slightly.
- Remove both socket head bolts (arrows).
- Remove driver's side storage compartment:
- Remove clutch pedal from master cylinder. To do this, pry out bolt lock using screwdriver (arrow -1-), remove bolt (arrow -2-) and depress clutch pedal.
Note:
^ For the following procedures, make sure that the clutch pedal does not press out switch -1- from securing clip, since the thread of the switch would be damaged and the switch would have to be replaced.
^ To ensure proper securing, the switch may only be installed once.
- Remove bolts for master cylinder (arrow -2) and for mounting bracket (arrow -3-).
- Pull complete pedal assembly somewhat toward seating compartment and remove clutch master cylinder -4-.
Installing
Installation is the reverse order of removal, while noting the following:
- Insert master cylinder so that the so that seal -1- with washer sits behind bearing mount and tighten bolts -2- to 20 Nm.
- Press connecting line -3- with guide -arrow A- into groove -arrow B- at mounting bracket.
A second technician is necessary for the next work step.
- Slide complete pedal assembly forward, toward transverse wall, insert bolt (arrow -3) and tighten by hand. At the same time, second technician must insert tube from plenum chamber into master cylinder.
- Tighten bolts for brake booster (arrows) to 25 Nm.
- Press securing clip -C- in to stop.
- Insert tube -B- into master cylinder until the tube engages audibly.
- Insert rubber grommet -D- into transverse wall above connecting tube/after -run hose-A-.
- Slide on after-run hose -A- to brake fluid reservoir to stop.
- Remove special tool 3094.
- Tighten socket head bolt (arrow) for pedal assembly to 25 Nm.
- Connect master cylinder to clutch pedal. Engage bolt lock into clutch pedal.
- Bleed clutch system after installing master cylinder, Refer to Clutch, MT, Service and Repair.
- Check adjustment of switch -1- above clutch pedal as follows:
^ Switch -1- must lie against clutch pedal -3- completely and must be completely activated.
^ Adjustment tolerance: gap measurement-a- between retaining clip and mounting bracket -2- or gap measurement -b- at switch -1- may be a maximum of 0.5 mm.
^ To adjust, hold clip and rotate switch -1 -.
Note: Connect clutch master cylinder with clutch pedal. Engage bolt lock in clutch pedal.
- Remove driver's side storage compartment:
- Always replace seal -C-.
- Make sure seal does not cover chassis opening and elevated edge of sheet metal.
- Insert E-Box in securing point -B- and tighten nuts -A- to 4 Nm.
- Press cover on by hand and tighten bolts -A- diagonally to 4 Nm (also see inscription on cover).
- Install engine wiring harness and connect harness connector in connector station.
- Install engine control module and if necessary, auxiliary relay carrier and auxiliary fuse holder.