Clutch Master Cylinder, Removing and Installing

Clutch master cylinder, removing and installing, 02M, 5 and 6 Spd. M/T

Special tools and equipment

T10005 Pliers:

VAG 1331 Torque Wrench:

Removing
- Request code on vehicles with coded radio if necessary.
- Disconnect battery with ignition switched off.





- 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 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 performed 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. Avoid damage to piston rod.
- Push clutch pedal in direction of arrow to engage it, and make sure it is located correctly.





- Install stop -A- for clutch pedal again.

Installed position:
Arm (arrow) points toward master cylinder -B-.
- After installing clutch master cylinder, bleed clutch system.