Removing and installing clutch master cylinder with mounting bracket installed — VW

Removing and installing clutch master cylinder with mounting bracket installed
Special tools and workshop equipment required
Hose clamps to 25 mm
3094
Pliers
T10005
Sealing tool
T10249
Torque wrench
V.A.G 1331
Removing
Note
Before replacing the clutch master cylinder due a suspected defect, use
Guided fault finding
Vehicle diagnostic tester
.
When performing work in the footwell, put cloths on the floor covering to protect it from possible brake fluid spills.
On vehicles with start/stop system, the clutch master cylinder and
clutch position sender
G476
form one unit and cannot be renewed individually
Electronic Parts Catalogue
.
Disconnect battery earth strap
Electrical system
Rep. gr.
27
Battery; Disconnecting and connecting battery
.
Remove battery and battery cover
Electrical system
Rep. gr.
27
Battery; Removing and installing battery
.
Remove lower dash panel trim on driver side
General body repairs, interior
Rep. gr.
68
Compartments/covers; Removing and installing dash panel trim on driver side
.
If fitted, remove
clutch pedal switch
F36
Chapter
.
Caution
Risk of leaking brake fluid.
During the following work, ensure that no brake fluid lands on longitudinal member or gearbox. If this does happen, clean the affected areas thoroughly.
Lay a lint-free cloth under clutch master cylinder.
To facilitate accessibility to clutch master cylinder, pull off side battery cover from plenum chamber bulkhead.
Clamp off supply hose
1
to clutch master cylinder with
hose clamps up to 25 mm
3094
.
Pull off supply hose
1
from connection
arrow
of clutch master cylinder
2
.
Pull out securing clip
3
for pipe/hose assembly to stop.
Pull out pipe/hose assembly
4
from clutch master cylinder
2
and seal.
Note
Alternatively,
sealing tool
T10249/1
can be used to clamp off the supply hose.
Clamping off the plastic supply hose with the
hose clamps up to 25 mm
3094
will cause a permanent deformation.
However, this does not damage the supply hose.
After removing the
hose clamp, up to 25 mm
3094
, the supply hose must be returned to its original shape.
Move clutch pedal to rest position.
Release clutch master cylinder operating rod from clutch pedal as follows:
Press sides of retainer inwards
in direction of arrow
using
pliers
T10005
.
Note
To assist clarity, clutch pedal is shown with mounting bracket removed.
Pull clutch pedal in direction of retainer
A
for
clutch pedal switch
F36
.
If fitted, disconnect electrical connector
1
from
clutch position sender
G476
.
Unclip wiring harness
2
from mounting bracket for clutch pedal
arrow
.
Note
The wire for the
clutch position sender
G476
is located on the right side of the mounting bracket for the clutch pedal.
Unscrew securing nuts
2
of clutch master cylinder
1
.
Remove clutch master cylinder
1
downwards.
Installing
Install in reverse order of removal, observing the following:
Insert clutch master cylinder in mounting.
Fit new securing nuts
2
for clutch master cylinder
1
, and tighten them to specified torque
Item
.
The retainer
A
must be fitted to the clutch master cylinder operating rod
B
.
Push clutch pedal in direction of
arrow
until it engages. Check that it is engaged securely.
If fitted, install
clutch pedal switch
F36
Chapter
.
If present, clip wiring harness
2
for
clutch position sender
G476
to mounting bracket for clutch pedal
arrow
.
Connect connector
1
to
clutch position sender
G476
.
Install lower dash panel trim on driver side
General body repairs, interior
Rep. gr.
68
Compartments/covers; Removing and installing dash panel trim on driver side
.
Press in pipe/hose assembly
4
at connection of clutch master cylinder
2
until securing clip
3
engages audibly.
Test line by tugging on it.
Push supply hose
1
onto connection
arrow
of clutch master cylinder.
After removing
hose clamps up to 25 mm
3094
, return supply hose to its original contour, if necessary.
If removed, fit side battery cover on stud of plenum chamber bulkhead.
Bleed clutch mechanism
Chapter
.
Install battery and battery cover
Electrical system
Rep. gr.
27
Battery; Removing and installing battery
.
Specified torques
Chapter
“
Assembly overview - pedal cluster
”