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 connecting tube of master cylinder 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.
^ Disconnect harness connector for Brake Fluid Level Warning Switch F34 from brake fluid reservoir.





^ Remove bolt - 1 -.
^ Carefully remove bolts - 3 - and - 4 - from brake booster using Torx insert T45.
^ Remove storage compartment on drivers side.





^ Disconnect clutch pedal from master cylinder. To do so, pry out bolt lock using screwdriver - arrow 1 - and pull out bolt - arrow 2 -.





Make sure that Clutch Pedal Switch F36 - 1 - is not pressed out of retaining clip. If the switch is pressed out the threads will be damaged and the switch must be replaced.

In order to assure sufficiently secure seating, Clutch Pedal Switch F36 - 1 - must not be installed more than once.
^ Unbolt - arrows 2 - master cylinder - 4 - out from passenger compartment.
^ Remove mounting bracket mounting bolt - arrow 3 -.
^ 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 - arrow -.

When doing this, second technician must guide hose/line assembly from plenum chamber into master cylinder.





^ Tighten mounting bolts - 3 - and - 4 -for master cylinder with brake booster.
^ Tighten mounting bolt - 1 - for brake fluid reservoir - 2 -.
^ 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 - arrow - for mounting pedal assembly to instrument panel carrier.
^ Connect master cylinder to clutch pedal. Engage new bolt in clutch pedal.
^ Bleed clutch system after installing master cylinder.

Tightening torques: