6 SPD. M/T 02X AWD
Master cylinder, removing and installing - 6 Spd. Manual Transmission 02X All Wheel Drive
Special tools, testers and auxiliary items required
^ Hose clamp 3094
^ Pliers V.A.G1922
Removing
Observe the notes on removing and installing clutch master cylinder and slave cylinder.
CAUTION!
^ Follow steps required when disconnecting battery.
- Remove rubber seal on plenum chamber in direction of - arrow -.
- Remove cover - 1 - from plenum chamber.
- With ignition switched off, disconnect battery Ground (GND) strap.
- Use screwdriver to pry off two caps - 3 -.
- Remove nuts - 4 - and take off two wiper arms - 2 -.
- Pull off clips - 1 - and remove cowl panel grille - 5 -.
Take electronics box out of plenum chamber as follows:
- Remove bolts - arrows - and take off cover.
- Use screwdriver to carefully pry off retaining strap - arrow -.
- Lay aside engine control module with connectors attached.
- Disconnect connectors - 2 - at console.
- Disconnect 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.
- Clamp supply hose - A - from brake fluid reservoir using hose clamp 3094. Disconnect hose from master cylinder and plug hose.
- Remove rubber grommet from bulkhead above connection line for supply hose.
- Pry out retaining clip - C - using a screwdriver and pull line/hose assembly - B - out slightly.
- Remove bolt for brake fluid reservoir - 1 - and disconnect connector for brake fluid level warning contact downward.
Note:
^ Brake fluid reservoir must not be removed.
- Remove vacuum line to brake servo - 1 -.
- Remove two TORX bolts - arrows -.
Note:
^ To simplify the illustration, the brake fluid reservoir has not been included.
^ The brake fluid reservoir must be moved slightly to the side in order to unscrew the upper TORX bolt.
- Remove storage compartment on drivers side.
- Removing over-center spring.
- Disconnect brake pedal from brake servo.
- Disconnect steering column from steering gear - arrow A -.
- Disconnect connectors from clutch pedal switch F36 - 1 -, brake light switch F - 2 - and accelerator pedal module - 3 -.
- If installed, disconnect connector from clutch pedal switch for engine start F194.
- Remove securing bolt for mounting bracket - arrow B - 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.
- Position spark plug connector pliers V.A.G1922 in clutch pedal recesses, press on sides of retaining clip and disconnect clutch pedal from master cylinder.
- Remove retaining clip - 1 - and remove clutch pedal - 2 -.
- Remove bolts - 3 - and remove master cylinder - 4 -.
Installing
Installation is in reverse order of removal. Note the following:
- Insert master cylinder - 4 - and tighten bolts - 3 - to 20 Nm.
- Insert 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. Second technician must guide hose/line assembly into 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 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.
- Tighten securing bolt - 1 - for brake fluid reservoir and connect connector at brake fluid level warning contact.
- Tighten hex socket head bolt - arrow B - for securing pedal cluster to instrument panel carrier to 25 Nm.
- Connect connectors - 1 -, - 2 - and - 3 -.
- If installed, connect connector for Clutch Pedal Starter Interlock Switch F 194.
- Connect brake pedal to brake servo.
- Secure steering column to steering gear - arrow A -.
- Install over-center spring.
- Install storage compartment on drivers side.
- Bleed clutch system.
- Insert electronics box and tighten nuts - arrows - to 4 Nm.
- Route engine wiring harness and plug in connector in connector console.
- Install engine control unit.
- 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.