Clutch Master Cylinder, Removing and Installing
Clutch master cylinder, removing and installing, 0A3, 6 Spd. M/T AWD
Special tools, testers and auxiliary items required
Hose clamps, up to diameter 25 mm 3094:
Pliers VAG 1922:
Removing
CAUTION:
^ Follow steps required when disconnecting battery.
^ On vehicles equipped with a telematics system, activate the telematics control module service mode before disconnecting the battery.
- Pull off rubber seal on plenum chamber in direction of - arrow -.
- Remove cover - 1 - from plenum chamber.
- With the ignition switched off, disconnect battery ground (GND) strap.
- Pry off the two caps - 3 -.
- Remove nuts - 4 - and remove the two wiper arms - 2 -.
- Remove clips - 1 - and disconnect cowl panel grille - 5 -.
Remove the electronics box from the plenum chamber as follows:
- Unscrew bolts - arrows - and take off the cover.
- Use screwdriver to carefully pry off retaining strap - arrow -.
- Lay aside engine control module with connectors attached.
- Disconnect connectors - 2 - at connector console.
- Remove electrical wiring connection - 1 -.
- Release catches - arrows - and lift auxiliary relay carrier out of electronics box.
- Pull engine wiring harness together with rubber grommet out through opening in electronics box.
- Remove nuts - arrows - and lift out electronics box - 1 -.
Note:
^ In the following steps make sure that no brake fluid escapes into the plenum chamber or onto the transmission below. If this does happen, clean the affected area thoroughly.
^ When performing work in the footwell, put cloths on the carpet to protect it from possible brake fluid spills.
- Pinch off supply hose - A - from brake fluid reservoir using hose clamp 3094. Disconnect hose from clutch master cylinder and plug hose.
- Remove rubber grommet from bulkhead above connection line for supply hose.
- Lever out retaining clip - C - using a screwdriver and then pull out line/hose assembly - B - slightly.
- Remove bolt for brake fluid reservoir - 1 - and disconnect connector for Brake fluid level warning contact downwards.
Note:
^ The brake fluid reservoir does not have to be removed.
- Remove vacuum line to brake servo - 1 -.
- Remove the two TORX bolts - arrows -.
Note:
^ To simplify the illustration, the brake fluid reservoir has not been included.
^ Brake fluid reservoir must be moved slightly to the side in order to unscrew upper Torx bolt.
- Remove storage compartment on drivers side.
- Removing over-center spring.
- Disconnect brake pedal from brake servo .
- Disconnect steering column from steering box - arrowA -.
- Disconnect connectors at clutch pedal switch - 1 -, brake pedal switch - 2 - and at accelerator pedal module - 3 -.
- If installed, disconnect connector from Clutch Pedal Starter Interlock Switch F194.
- Remove securing bolt for mounting bracket - arrowB - and remove entire pedal cluster.
Release master cylinder operating rod from clutch pedal as follows:
Note:
^ When releasing the operating rod, make sure that clutch pedal does not collide with mounting bracket for clutch pedal switch - arrow -. The mounting bracket could otherwise break off.
- Insert pliers V.A.G 1922 in recesses on clutch pedal, press on sides of retaining clip and Disconnect clutch pedal from master cylinder.
- Disconnect retaining clip - 1 - and remove clutch pedal - 2 -.
- Remove bolts - 3 - and remove clutch master cylinder - 4 -.
Installing
Installation is performed in reverse sequence; note the following:
- Install clutch master cylinder - 4 - and tighten bolts - 3 - to 20 Nm.
- Install retaining clip - 1 - in clutch pedal.
- Lock clutch pedal in position by pressing in direction of - arrow -. Make sure retaining clip - 1 - engages correctly in clutch pedal.
A second technician is required for the next step.
- Insert entire pedal cluster and tighten bolt - 1 - by hand. The second technician should guide hose/line assembly into clutch master cylinder from plenum chamber.
- Tighten bolts for brake servo - arrows - to 25 Nm.
- Press in retaining clip - C - as far as it will go.
- Insert hose/line assembly - B - in clutch master cylinder and make sure that it engages audibly.
- Install rubber grommet - D - onto connecting line for supply hose - A - at bulkhead.
- Push supply hose - A - from brake fluid reservoir on as far as it will go.
- Remove hose clamps 3094.
- Screw in securing bolt - 1 - for brake fluid reservoir and Connect connector at brake fluid level warning contact.
- Tighten hexagon socket head bolt - arrowB - for securing pedal cluster to instrument panel carrier to 25 Nm.
- Connect connectors - 1 -, - 2 - and - 3 -.
- If installed, attach connector for Clutch Pedal Starter Interlock Switch F194.
- Connect brake pedal to brake servo.
- Secure steering column to steering box - arrowA -.
- Install over-center spring.
- Install storage compartment on drivers side.
- Bleed clutch system.
- Install electronics box and tighten nuts -arrows- to 4 Nm.
- Route engine wiring harness and Connect connector in connector console.
- Install engine control module.
- If applicable, install auxiliary relay carrier and auxiliary fuse carrier.
- Press on cover (hand-tight) and tighten bolts in diagonal sequence to 4 Nm.
- Follow steps required after connecting battery.
Note:
^ Upon re-connecting the battery, remember to check and activate the vehicle equipment (radio, clock, convenience electrics etc.).