Removing, installing and servicing pedal cluster for vehicles with 169 kW engine — AUDI

Attention
The brake pedal travel must not be shortened by additional floor coverings.
Note:

Grease all bearings prior to assembly with solid lubricating paste, part no. G 052 142 A2

Coil spring
Insert U-shaped end in pedal bracket
Insert other end in grommet inserted in clevis

Pedal bracket
Do not take out to remove brake or clutch pedal

Supply hose
From brake fluid reservoir to clutch master cylinder

Circlip
Replace, attach to shaft of pedal bracket

Support spring
Brown mark
Do not grease spring
Only grease bearings on pedal/pedal bracket
Removing and installing => Fig.
3

Over-centre spring
Red mark
Do not grease spring
Only grease bearings on pedal/pedal bracket
Removing and installing => Fig.
4

Circlip
Replace, attach to shaft of pedal bracket

Hexagon bolt, 25 Nm
Insert in clevis and bolt to clutch pedal

Clutch pedal with swing support
Fixed in position by setting of clevis
Attach to shaft of pedal bracket
Can be removed and installed without taking out pedal bracket.
Available as replacement part with moulded bushing; bushing cannot be replaced

Self-locking nut, 25 Nm
Always replace
Bolt pedal bracket to bulkhead/connector plate

Pushrod for servo unit
Lock nut
Tighten after adjusting clevis

Grommet
Insert in clevis

Pin
Insert in clevis and brake pedal

Clevis of brake servo
Adjusting:

Vehicles with pneumatic brake servo => Page
47-43
, Fig.
1
Vehicles with hydraulic brake servo =>Page
47-44
, Fig.
2

Circlip
Always replace
Fit onto pin

Circlip
Replace, attach to shaft of pedal bracket

Brake pedal
Attach to shaft of pedal bracket
Can be removed and installed without taking out pedal bracket.
Available as replacement part with moulded bushing; bushing cannot be replaced

Shim
Self-locking nut, 25 Nm
Always replace

Brake light switch
Adjusting:

Press brake pedal
Press in brake light switch as far as it will go
Pull back brake pedal by hand as far as stop

Bleeder valves
Adjust with clevis in position

Press brake/clutch pedal
Press in bleeder valve as far as it will go
Pull back brake/clutch pedal by hand as far as stop

Clip
Press home in pedal bracket

Cheese-head bolt, 20 Nm
Screw master cylinder to pedal bracket

Clevis
With welded-on nut, thread: M8
Adjusting clevis => Page
46-38
, Fig.
1

Clutch master cylinder
Replace if leaking

Fig.3
Inner support spring (brown)

Remove retainer from support pin
Insert clamp -3117- downwards as shown by gently pressing clutch pedal, then actuate clutch pedal accordingly and while doing so remove over-centre spring from support pin/clutch pedal

Note:

The inner support spring can only be removed after taking out the outer over-centre spring.

Fig.4
Outer over-centre spring (red)

Note:

The illustration shows the clamp with the pedal bracket removed.

Remove retainer from support pin
Insert clamp -3117- as shown, press clutch pedal and while doing so remove over-centre spring from pedal bracket/clutch pedal.