Clutch Master Cylinder: Service and Repair

Master Cylinder

Special tools, testers and auxiliary items required

• Pliers (T10005)

• Torque wrench 5 to 50 Nm (V.A.G 1331)

Removing

- First determine whether a coded radio is installed. In this case, determine anti-theft coding.

- Disconnect battery ground (GND) cable with ignition switched off.

- Disconnect intake air duct - 1 - and connector - 2 - from Mass Air Flow (MAF) sensor (G70).





- Remove bolts - 3 - and - 4 -.

- Remove complete air filter.

- Remove control module and ABS hydraulic unit.

• For the following work, make sure brake fluid does not come into contact with longitudinal member or transmission. However, in case of contact clean this area thoroughly.

- Lay lint-free cloth under master cylinder.

- Disconnect return hose - A - to brake fluid reservoir and seal.





- Disengage clip - B - using screwdriver and pull until stop out of master cylinder.

- Disconnect hose/line assembly - C - from master cylinder and seal.

- Remove cover in driver's side footwell.

Release operating rod/master cylinder from clutch pedal as follows:

- Pull clutch pedal slightly into passenger compartment.

- Press both sides of mount inward using pliers ( T10005 ) - arrows -.





- Now, remove complete mounting bracket for clutch pedal as follows:

- First remove connecting panel - A - - arrows 1 -.





- Then remove nuts - arrows 2 - for bracket - B -.

- Remove bracket.

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





- Then press master cylinder first to stop in direction of - arrow 1 -.





It must not be covered in upper area of bearing for over-center spring - arrow 2 -.

- Then swing it in direction of - arrow 3 - out of bracket.

Installing

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

- Mount - A - must be located on operating rod - B - of master cylinder.





- Pull piston rod slightly out of master cylinder and hold in place using pliers.

- At the same time, press clutch pedal in direction of - arrow - to engage, while doing so ensure correct engaging.

- Reinsert stop - A - for clutch pedal.





Installation Position

The holder - arrow - points to master cylinder - B -.

- Bleed clutch system after installing clutch master cylinder => [ Clutch System, Bleeding ] Procedures.