Removing and installing clutch cable (automatic adjustment) — VW

In cases of complaint check function of clutch cable before removal => Page
30-5
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Removing

Disconnect earth strap from battery

Note:

Note radio coding for vehicles with coded radio.

If no retaining strap is present then the adjusting mechanism must be tensioned with the retaining strap illustrated to enable it to be removed and installed. It is enclosed with new cables to tension the adjusting mechanism.
The ring (arrow) on retaining strap must be cut open.

Hook retaining strap eye on, above protective sleeve (arrow).

Fully depress clutch pedal onto stop at least 5 times.
Move clutch release lever approx. 10 mm, opposite direction of operation (direction of arrow). The clutch release lever must move freely.

The adjusting mechanism will be compressed.

Hook retaining strap tabs onto adjustment mechanism pins (arrows) (2nd mechanic) required.
Unhook clutch cable at gearbox operating lever.
Pull rubber buffer out of support on gearbox.

Pull stowage compartment, below dash panel, out of mountings but first push stops in direction of arrow.

Unbolt cover (arrows)
Unhook relay plate from mountings;

Note:

Do not pull connectors off relays and wiring.

Unhook electric wiring from mountings
Remove cover for clutch pedal from mounting bracket (arrows -1- and -2-).

Unhook clutch cable from clutch pedal (arrow).

Remove clutch cable from retainers (arrows).
Take clutch pedal out.

Installing

(Clutch cable under tension)

Lubricate clutch cable clutch pedal mounting point with MoS2 grease.
Push clutch cable through bulkhead and clip bellows in position.
Hook clutch cable into clutch pedal.

Hook clutch cable onto gearbox as follows:

Fit rubber buffer -3-.
Pull cable sleeve -2- in normal direction of travel and insert buffer in clutch release lever -1-

Clip clutch cable into retainers (arrows).

Note:

Do not kink clutch cable when doing this. The function of the adjusting mechanism cannot otherwise be guaranteed.

After installing clutch pedal remove retaining strap (arrows).
Check clutch cable function =>Page
30-5

Installing

(Clutch cable not under tension)

Lubricate clutch cable clutch pedal mounting point with MoS2 grease.
Push clutch cable through bulkhead.
Hook clutch cable into clutch pedal (arrow)

Attach retaining strap -A-
Pull end piece of cable in direction of arrow -1- and hold in this position, at the same time move the cable sleeve with the adjusting mechanism -B- to and fro several times, until it can be pressed together in direction of bulkhead (direction of arrow -2-).

Hook retaining strap tabs onto adjustment mechanism pins (arrows) (2nd mechanic) required.
Fit bellows into bulkhead.

Hook clutch cable onto gearbox as follows:

Fit rubber buffer -3-.
Pull cable sleeve -2- in normal direction of travel and insert buffer in clutch release lever -1-

Clip clutch cable into retainers (arrows).

Note:

Do not kink clutch cable when doing this. The function of the adjusting mechanism cannot otherwise be guaranteed.

After installing clutch pedal remove retaining strap (arrows).
Check clutch cable function =>Page
30-5

Locate cover on mounting bracket (arrows -1- and -2-).
Insert relay plate into mounting; check wiring and relay connectors and press fully home if necessary.
Install cover and stowage compartment below dash panel.