Clutch Master Cylinder: Service and Repair

Clutch master cylinder, removing and installing

Special tools and equipment





^ T10005 Pliers





^ VAG1331 Torque Wrench

Removing





^ Remove intake hose -1-, connector -2- and hose -3- from Mass Air Flow Sensor.
^ Remove complete air cleaner housing, to do this, unscrew bolts -4- and - 5 -
^ Disconnect supply hose -A- to brake fluid reservoir and seal it.





^ Remove clip -B-, which secures line/hose to clutch master cylinder.
^ Separate line/hose assembly -C- from master cylinder and seal it.
^ Remove covers/lower driver's side.
^ Turn clutch pedal switch 45° to the left and pull out from support.





^ Separate master cylinder operating rod from clutch pedal as follows:
^ Pull clutch pedal lightly toward passenger compartment.
^ Press both sides of mounting inward using pliers T10005 (arrows).





^ Remove entire clutch pedal support as follows:
^ Remove connecting plate -A- first (arrows -1-).
^ Remove securing nuts (arrows -2-) for support -B-.
^ Take off mounting bracket.





^ Turn stop -A- of clutch pedal in direction of arrow and remove.





^ Push master cylinder first in direction of arrow -1- onto stop.
It must not be covered in upper area by over center spring mounting (arrow -2-).
^ Swing it in direction of arrow -3- out of mounting bracket.

Installing
Installation is carried out in the reverse sequence. When installing note the following:





^ Retainer -A- must be on clutch master cylinder operating rod -B-.
^ Pull piston rod out of master cylinder slightly and hold using a pair of pliers.
^ Push clutch pedal in direction of arrow to engage it, and make sure it is located correctly.





^ Install stop -A- for clutch pedal again.

Installation position:
The arm (arrow) points toward the master cylinder -B-.
^ After installing clutch master cylinder, bleed clutch system.