Master Cylinder, Removing and Installing

Master cylinder, removing and installing, 01A, 5 SPD. M/T (AWD)

Special tools, testers and auxiliary items required

Hose clamp 3094:

Torque wrench V.A.G. 1331:

Removing
^ Check whether a coded radio is installed. If so, obtain anti-theft coding.
^ Disconnect battery Ground (GND) strap with ignition switched off.
^ Place a lint-free cloth into plenum chamber beneath return hose to brake fluid reservoir.





^ Clamp off return hose - A - to brake fluid reservoir using hose clamps 3094, disconnect at master cylinder connecting line and seal.
^ Remove grommet for return hose - A - from bulkhead.
^ Pull out clip - C - to stop using a screwdriver and then pull hose/line assembly - B - out slightly.





^ Remove bolt for brake fluid reservoir - 1 - and disconnect connector for Brake Fluid Level Warning Switch F34 downward.
Brake fluid reservoir is not removed.





^ Disconnect vacuum line to brake booster - 1 -
^ Remove Torx bolts - arrows -
For clarity, brake fluid reservoir is not designated in illustration.
To remove upper Torx bolt, brake fluid reservoir must be swung gently to side.
^ Remove storage compartment on drivers side.





Release operating rod/master cylinder from clutch pedal as follows:
^ Insert a standard needle-nose pliers - 1 - into clutch pedal recesses.
^ Press mount - 2 - together.
^ Pull clutch pedal gently into passenger compartment.
^ Pull operating rod and mount to engine compartment from clutch pedal direction of - arrow -





^ Remove master cylinder - arrow 1 - from passenger compartment - arrows 2 -.
^ Remove mounting bolt - arrow 3 - for mounting bracket.
^ Pull complete pedal assembly slightly toward passenger compartment.
^ Remove master cylinder.

Installing
Installation is in reverse order of removal. Note the following:





^ Insert master cylinder so that seal - 1 - and washer make contact behind mounting bracket.
^ Tighten bolts - 2 - to tightening torque.
^ Press connecting line - 3 - with guide - arrow A - into recess - arrow B - on mounting bracket.





A second technician is required for the following step.
^ Slide complete pedal assembly toward front to bulkhead and insert bolt - 1 -.
^ When doing this, second technician must guide hose/line assembly from plenum chamber into master cylinder.





^ Tighten mounting bolts - arrows - for master brake cylinder with brake booster.
^ Connect vacuum line to brake booster - 1 -.





^ Tighten mounting bolt - 1 - for brake fluid reservoir.
^ Connect harness connector to Brake Fluid Level Warning Switch F34 on brake fluid reservoir.





^ Press in clip - C - in direction of - arrow - to stop.
^ Insert hose/line assembly - B - in master cylinder until it engages audibly.
^ To check, pull on hose/line assembly.
^ Insert rubber grommet - D - for return hose - A - into bulkhead.
^ Push return hose - A - to stop onto connecting tube of master cylinder.
^ Remove hose clamp 3094.





^ Tighten bolt - 1 - for mounting foot pedal assembly to instrument panel carrier.





Connect operating rod/master cylinder to clutch pedal as follows:
^ Mount - A - must be located on operating rod - arrow - of master cylinder.
^ Insert mount into guide on clutch pedal and press clutch pedal to bulkhead until it engages, ensure correct engaging.
^ To check engaging, pull clutch pedal gently into passenger compartment and press both ends of mount to clutch pedal using screwdriver.
^ Bleed clutch system after installing clutch master cylinder.

Tightening torques: