Removing and installing over-centre spring, mounting bracket for clutch pedal installed — VW

Removing and installing over-centre spring, mounting bracket for clutch pedal installed
Special tools and workshop equipment required
Torque wrench
V.A.G 1331
Removing
Disconnect battery
Electrical system
Rep. gr.
27
Battery; Disconnecting and connecting battery
.
Push driver seat as far back as possible and move steering wheel to highest position.
Remove driver side storage compartment and cover
General body repairs, interior
Rep. gr.
68
Compartments/covers; Removing and installing dash panel end trim on driver side
.
Unscrew screws
arrows
and pull fuse holder
1
downwards off bracket
Electrical system
Rep. gr.
97
Relay carriers, fuse carriers, electronics boxes; Overview of fitting locations - relay carriers, fuse carriers, electronics boxes
.
Remove footwell vent on driver's side
1
Heating, air conditioning
Rep. gr.
87
Air duct; Assembly overview - air routing and air distribution in passenger compartment
.
Remove crash bar
A
. First remove bolt
B
and then bolt
C
.
Remove footwell trim by removing nuts
arrows
.
Unscrew bolt
arrow
from universal joint and pull universal joint from steering rack in
direction of arrow
Running gear, axles, steering
Rep. gr.
48
Steering column; Assembly overview – steering column
.
Remove clutch pedal
1
from mounting bracket
3
. To do this, unscrew nut
2
and pull out bolt
5
.
Note
Clutch pedal remains hooked to operating rod of clutch master cylinder.
Swing clutch pedal down slightly and remove over-centre spring
4
from mounting bracket.
Installing
Install in reverse order of removal, observing the following:
Note
Renew self-locking nuts.
Insert over-centre spring from above in mounting bracket.
Receptacle
arrow
for tip
A
of clutch pedal must stand vertically.
Insert tip of clutch pedal in bearing recess of over-centre spring.
Depress clutch pedal slightly, push bolt through and tighten self-locking nut.
Caution
If over-centre spring is improperly installed, it will jump uncontrolled out of mounting bracket.
Check function of over-centre spring by pressing clutch pedal a few times.
Attach steering column universal joint to steering rack
Running gear, axles, steering
Rep. gr.
48
Steering column; Assembly overview – steering column
.
Install crash bar
A
, (bolt
B
and bolt
C
).
Remove footwell vent on driver's side
Heating, air conditioning
Rep. gr.
87
Air duct; Assembly overview - air routing and air distribution in passenger compartment
.
Fasten fuse holder
1
to bracket/relay carrier using screws
arrows
Electrical system
Rep. gr.
97
Relay carriers, fuse carriers, electronics boxes; Overview of fitting locations - relay carriers, fuse carriers, electronics boxes
.
Remove driver side cover and storage compartment
General body repairs, interior
Rep. gr.
68
Compartments/covers; Removing and installing dash panel end trim on driver side
.
Connect battery
Electrical system
Rep. gr.
27
Battery; Disconnecting and connecting battery
.
Perform basic setting for
steering angle sender
G85
using
Vehicle diagnostic tester
.
Specified torques
Chapter
“
Assembly overview - pedal cluster
”
Component
Specified torque
Bracket for relay carrier to crash bar (bolt M 6)
4.5 Nm
Crash bar to mounting bracket of steering column (bolt M 8)
20 Nm