Volkswagen Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ 3309 Release tool
• ◆ 10-208 A Pliers
• ◆ V.A.G 1331 Torque wrench

Removing

• ‒ Remove coolant expansion tank and lay to one side.

Note:

Do not open cooling system.

• ‒ Remove pipe from master cylinder and seal.
• ‒ Pull supply hose off brake fluid reservoir and seal.
• ‒ Unhook relay plate from left retainer.
• ‒ Remove protection plate between relay plate and pedal cluster =>Page 30-7 , removing and installing over-centre spring.

→ Separate master cylinder operating rod from clutch pedal as follows:

• ‒ To release insert release tool 3309 in the clutch pedal cut-out (arrow A). The inscription "top/oben" (B) points towards dash panel.
• ‒ With pliers 10-208A positioned in the recesses (arrows C) press release tool together.

Note:

The clutch pedal will be pushed onto stop in the passenger compartment after completely removing the over-centre spring, if necessary it can be pulled into the passenger compartment.

• ‒ → Remove mounting bracket support (arrow A) by removing bolt (arrow B) and nut (arrow C).

• ‒ → Remove master cylinder from the passenger compartment by removing both securing nuts (arrows) one each side of the clutch pedal -A-.

• B- 13 mm, 3/8" square drive deep socket, commercial type

Installing

Installation is carried out in the reverse sequence, when doing this note the following:

• ‒ → The retainer -A- must be fitted to the master cylinder operating rod -B-.
• ‒ To engage press clutch pedal towards bulkhead (direction of arrow). Ensure correctly located.
• ‒ Bleeding clutch system after installing master cylinder=>Page 30-20 .