01X Transmission

Master Cylinder

Special tools, testers and auxiliary items required

• Hose clamp (3094)

• Spark plug connector pliers (VAG 1922)

Removing

Observe the notes on removing and installing master cylinder and slave cylinder. Refer to => [ Master Cylinder and Slave Cylinder ] Master Cylinder and Slave Cylinder.

CAUTION!
• Follow steps required when disconnecting battery.

- Pull off rubber seal on plenum chamber in direction of - arrow -.





- Remove cover - 1 - from plenum chamber.

- With ignition switched off, disconnect battery Ground (GND) cable.

- Use screwdriver to pry off the two caps - 3 -.





- Remove nuts - 4 - and detach the two wiper arms - 2 -.

- Pull off clips - 1 - and detach cowl panel grille - 5 -.

Take the electronics box out of the 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 bracket.





- 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 -.





• In the following steps make sure that no brake fluid leaks 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 out pipe/hose assembly - B - slightly.

- Remove brake fluid reservoir bolt - 1 - and disconnect connector for brake fluid level warning contact downward.





• Brake fluid reservoir must not be removed.

- Remove vacuum line to brake servo - 1 -.





- Remove two TORX bolts - arrows -.

• 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 remove the upper TORX bolt.

- Remove storage compartment on driver's side.

- Removing over center spring. Refer to => [ Over Center Spring ] Over Center Spring.

- Disconnect brake pedal from brake servo.





- Disconnect steering column from steering gear- arrow A -. Refer to => Steering Steering





- Disconnect connectors from clutch pedal switch - 1 -, brake light switch - 2 - and accelerator pedal module - 3 -.

- If installed, disconnect connector from clutch pedal starter interlock switch (F194).

- Remove securing bolt for mounting bracket - arrow B - and remove entire pedal cluster.

Release master cylinder operating rod from clutch pedal as follows:





• 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.

• The clutch pedal switch (F 36) => [ (Item 6) ] Pedal Cluster Assembly Overview and clutch pedal switch (F194 ) => [ (Item 14) ] Pedal Cluster Assembly Overview. Only install one time so as to ensure a firm fit in pedal cluster.

- Apply spark plug connector pliers (VAG 1922 ) in clutch pedal recesses, press on sides of retaining clip => [ (Item 9) Retaining clip ] Hydraulic System Assembly Overview and detach 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 perform in reverse sequence. Note the following:

- Install 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. The second technician should guide pipe/hose 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 pipe/hose assembly - B - in master cylinder and make sure that it engages audibly.

- Install rubber grommet - D - onto connecting pipe 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 bolt - 1 - for brake fluid reservoir and connect connector at brake fluid level warning contact.





- Tighten bolt - arrow B - for securing pedal cluster to instrument panel carrier to 25 Nm.





- Connect connectors - 1 -, - 2 - and - 3 -.

- If installed, plug in connector for clutch pedal switch (F194).

- Connect brake pedal to brake servo.

- Secure steering column to steering gear - arrow A -.

- Install over center spring. Refer to Over Center Spring.

- Install storage compartment on driver's side.

- Bleed clutch system. Refer to => [ Clutch Hydraulic System Bleeding ] 01X, 6-Speed Front-Wheel Drive M/T.

- Insert electronics box and tighten nuts - arrows - to 4 Nm.





- Route engine wiring harness and connect connector in console.

- Install engine control module.

- 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.