Clutch Master Cylinder: Service and Repair
Clutch Master Cylinder
Special tools, testers and auxiliary items required
• Hose Clamps up to 25 mm Diameter. (3094)
• Pliers (V.A.G 1922)
Removing
• Before replacing the clutch slave cylinder, perform a function test first. Refer to => [ Master Cylinder and Slave Cylinder General Information ] Description and Operation.
• When working in floor area, cover the carpet with a cloth to protect against any leaking brake fluid.
- Pull of rubber seal on plenum chamber in direction of - arrow -.
- Remove cover - 1 - over plenum chamber.
CAUTION!
• Observe procedures for disconnecting battery.
• Explain to the customer that they should not rest their foot on the clutch pedal. It can interfere with the self-bleeding function of the clutch system, because the bleeder hole in the clutch slave cylinder can not perform its function.
- With ignition switched off, disconnect negative terminal on battery.
- Pry off cover caps - 3 - with screwdriver.
- Turn nuts - 4 - downward and remove both wiper arms - 2 -.
- Remove clamps - 1 - and remove cowl vent grille - 5 -.
Remove E-box in plenum chamber as follows:
- Remove screws - arrows - and remove cap.
- Carefully pry off retaining brackets - arrow - with help of a screwdriver.
- Lay aside ECM with connectors connected.
- Remove connector - 2 - at edge connector.
- Remove electrical wiring harness - 1 -.
- Release catches - arrows - and remove additional relay carrier in E-box upward.
- Remove engine wiring harness together with rubber grommet from notch in E-box.
- Remove bolts - arrows - and lift E-box - 1 - out.
• While performing the following work, make sure that no brake fluid comes into contact with plenum chamber or with transmission below. If this happens, these areas must be cleaned thoroughly.
• When working in floor area, cover the carpet with a cloth to protect against any leaking brake fluid.
- Clamp shut supply hose - A - to reservoir/brake fluid with Hose Clamps up to 25 mm Diameter. (3094), remove at clutch master cylinder and seal off.
- Remove rubber grommet over supply hose connecting pipe from cross panel.
- Pry retaining clip - C - out with a screwdriver and then pull hose/line assembly - B - out a little.
- Remove the bolt for brake fluid reservoir - 1 - and pull the connector for the Brake Fluid Level Sensor off downward.
• The brake fluid reservoir is not removed.
- Remove the vacuum pipe to brake booster - 1 -.
- Remove both Torx(R) bolts - arrows -.
• To improve clarity, the brake fluid reservoir is not indicated.
• To remove the upper Torx(R) bolt, the brake fluid reservoir must be slightly pivoted to the side.
- Remove storage compartment on driver side.
- Over-center spring, removing. Refer to => [ Over-Center Spring ] Over-Center Spring.
- Disconnect brake pedal from brake booster.
- Disconnect steering column from steering gear - arrow A - => Suspension Front and All Wheel Drive 48.
- Disconnect the connector on the Clutch Pedal Switch (F 36) - 1 -, Brake Lamp Switch - 2 - and on the accelerator pedal module - 3 -.
- If equipped, disconnect connector from Clutch Pedal Starter Interlock Switch (F194).
- Remove mounting bracket bolt - arrow B - and remove entire pedal assembly.
Release clutch master cylinder actuator rod from clutch pedal as follows:
• When releasing, make sure clutch pedal does not run into clutch pedal switch mount - arrow -. The mount could break off.
• To ensure sufficient secure seating for Clutch Pedal Switch (F 36) => [ (Item 6) ] Pedal Assembly Component Overview and Clutch Pedal Starter Interlock Switch (F 194 ) => [ (Item 14) ] Pedal Assembly Component Overview, these switches must only be installed once.
- Place Spark Plug Pliers (V.A.G 1922) in clutch pedal recesses, press mount => [ (Item 9) Base block ] Removal and Replacement together and disconnect clutch pedal from clutch master cylinder.
- Remove securing clamps - 1 - and clutch pedal - 2 -.
- Remove bolts - 3 - and remove clutch master cylinder - 4 -.
Installing
Install in reverse sequence; note the following points:
- Insert clutch master cylinder - 4 - and tighten bolts - 3 - to 20 Nm.
- Insert mount - 1 - in clutch pedal.
- Press clutch pedal in direction of - arrow - until it engages. Ensure mount - 1 - is secured correctly in clutch pedal when doing so.
A second technician is needed for the following step.
- Insert entire pedal assembly and hand-tighten bolt - 1 -. At the same time, second technician must guide hose/line assembly from plenum chamber out into clutch master cylinder.
- Tighten brake booster bolts - arrows - to 25 Nm.
- Press in securing clip - C - to stop.
- Push hose/line assembly - B - into clutch master cylinder until line audibly engages.
- Insert rubber grommet - D - over connecting pipe/supply hose - A - in cross panel.
- Push supply hose - A - onto brake fluid reservoir to stop.
- Remove Hose Clamps up to 25 mm Diameter. (3094 ).
- Install brake fluid reservoir bolt - 1 - and connect connector at brake fluid level sensor.
- Tighten hex head bolt - arrow B - for securing pedal assembly to instrument panel carrier to 25 Nm.
- Connect connectors - 1 -, - 2 - and - 3 -.
- If equipped, connect Clutch Pedal Starter Interlock Switch (F194) connector.
- Connect brake pedal with brake booster. Refer to =>
Brakes and Traction Control Brakes and Traction Control
- Secure steering column to steering gear. Refer to - arrow A - => Steering Steering
- Over-center spring, installing => [ Installing ] Over-Center Spring.
- Install storage compartment on driver side.
- Bleed clutch system. Refer to => [ Clutch System, Bleeding ] 02XA Transmission.
- Insert E-box and tighten the nuts - arrow - to 4 Nm.
- Route engine wiring harness and connect connector in connector station.
- Install Engine Control Module (ECM).
- Install additional relay carrier or additional fuse holder, if necessary.
- Press in cap by hand and tighten bolts in diagonal sequence to 4 Nm.
- Observe procedures for connecting battery.