Renewing bellows with clutch actuator — VW

🧭 Before you start

Fits: VW Golf Cabriolet (517, 2011–2016), VW Passat B7 saloon (362, 2010–2014), VW Passat B7 Variant (365, 2010–2014), VW CC (358, 2012–2017)

• Opens: power steering fluid

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• The area around the clutch actuator must always be clean and dry. Any contamination may cause leaks at a later point.
• Always make sure that the bleeder connection (arrow) is properly sealed so that no oil can escape before turning over the mechatronic unit.
• Clean guide bush thoroughly before any work step, since any kind of contamination may cause leaks at a later point.
• The following check is very important for the further procedure.
• Do not fill hydraulic fluid until the following steps have been completed.

📋 Procedure

1. ⚠ Risk of damaging mechatronic unit.To achieve the desired results when performing repairs, it is important to work with the greatest possible care and cleanliness, and to use proper tools which are in perfect condition.The piston of the clutch actuator is magnetic. Remove new clutch actuators from their packaging only immediately before installing them to ensure the highest possible level of cleanliness. Install the clutch actuators immediately after they have been removed from their packaging, and do not place them anywhere else. — Removing mechatronic unit
2. Place mechatronic unit onto an even surface such as a workbench. The oil filler plug (arrow) faces upwards. [Note: The area around the clutch actuator must always be clean and dry. Any contamination may cause leaks at a later point.]
3. Clean area (1) around clutch actuators using cleaning solution D 009 401 04 or a bottle (2) with washing-up liquid. Remove any stubborn dirt with a brush. Then, use a lint-free cloth to thoroughly clean area (1) again. [Note: Always make sure that the bleeder connection (arrow) is properly sealed so that no oil can escape before turning over the mechatronic unit.]
4. Turn over mechatronic unit, and set it down with the clutch actuators facing upwards.
5. Use a screwdriver (2) to lever bellows (1) off mechatronic unit. [Note: Clean guide bush thoroughly before any work step, since any kind of contamination may cause leaks at a later point.]

6. Fit guide bush (2) with the large opening facing upwards onto mechatronic unit, as shown in illustration, and hold it with one hand. Use the other hand to pull out clutch actuator (1) to stop.
7. Carefully remove guide bush. Do not pull out clutch actuator (1) any further when doing this. [Note: The following check is very important for the further procedure.]
8. Check area around clutch actuator (1) for leaks. [Note: Do not fill hydraulic fluid until the following steps have been completed.]
9. Set down mechatronic unit in such a way again that the oil filler plug (arrow) faces upwards.
10. Clean area around seal (2) using cleaning solution D 009 401 04 or a bottle (1) with washing-up liquid. Then, let the washing-up liquid drip off, and dry it off with a lint-free cloth as necessary.
11. Set down mechatronic unit with the clutch actuators facing upwards. Always make sure that the bleeder hole (arrow) is properly sealed so that no oil can escape. [Note: Extreme care and a high level of cleanliness are required for any work. Therefore, always make sure that no dirt gets into the opening when pulling out the clutch actuator.]
12. Pull both clutch actuators out of mechatronic unit. [Note: Clean guide bush thoroughly before any work step, since any kind of contamination may cause leaks at a later point.]
13. ⚠ Risk of damaging mechatronic unit.To achieve the desired results when performing repairs, it is important to work with the greatest possible care and cleanliness, and to use proper tools which are in perfect condition.The piston of the clutch actuator is magnetic. Remove new clutch actuators from their packaging only immediately before installing them to ensure the highest possible level of cleanliness.Install the clutch actuators immediately after they have been removed from their packaging, and do not place them anywhere else. — Lightly coat sealing lip (arrow) of seal (2) with oil, and slide it to stop into guide bush (1).
14. Carefully fit clutch actuator (1) with guide bush (2) onto opening in mechatronic unit. Hold guide bush with one hand, and use the other hand to slide clutch actuator 30 mm into mechatronic unit.
15. Carefully remove guide bush. Do not pull out clutch actuator again when doing this.
16. Carefully push clutch actuator further into mechatronic unit until bellows rest against opening.
17. Use 4 fingers to engage catch (2) of bellows (1) firmly in mechatronic unit.
18. Install the remaining clutch actuator in the same way.
19. Remove old seal from mechatronic unit, and clean groove for seal ((highlighted in green)) before installing a new seal. [Note: The seal fits only in one position.]
20. Fit new seal all-round into groove in mechatronic unit. The nub on the seal (lower arrow) must be seated in the recess on the mechatronic unit (upper arrow).
21. If the oil in the mechatronic unit has been drained, replenish it .
22. Installing mechatronic unit .

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