Volkswagen Workshop Service and Repair Manuals

Removing and installing mounting bracket, Golf 2004 ► Special tools and workshop equipment required

t  Hose clamps to 25 mm -3094-

t  Torque wrench -V.A.G 1331-

t  Spring-type clip pliers -VAS 5024 A-

t  Sealing tool -T10249- Removing LHD –  First check whether a coded radio is fitted. If so, obtain anti-theft code. –  Remove battery and, if necessary, detach backwall of battery box → Electrical system; Rep. gr.27. Continuation for all   Note t  During the following work, ensure that no brake fluid lands on longitudinal member or gearbox. If this does happen, clean the affected areas thoroughly. t  Place a lint-free cloth under the master cylinder.

–  Clamp off supply hose to master cylinder using hose clamp -3094-.

–  If necessary, loosen spring-type clip -3- with assembly tool -VAS 5024- and pull supply hose off master cylinder. –  In addition, for disconnecting, you can close it with the sealing tool -T10249/1- (⇒ figure above). –  Release securing clip -2- using screwdriver or a pointed object and pull pipe/hose line or plastic line -1- off master cylinder. –  Unclip clutch position sender -G476- from master cylinder -arrow- and remove with electrical connector attached -4-.   Note When performing work in the footwell, put cloths on the carpet to protect it from possible brake fluid spills.

–  Remove trim and cover below trim on drive side → General body repairs, interior; Rep. gr.68. –  Remove cable guide -2- from steering column. –  Remove footwell vent -3-. → Heating, air conditioning; Rep. gr.80

The crash bar -1- in front of clutch pedal -2- may be secured in different ways. Attachment with 2 bolts –  Unbolt crash bar (2 bolts).

Attachment with 1 bolt –  Remove crash bar -1- (1 bolt -2-).

If fitted, remove damping -arrow- from lower area of clutch pedal mounting bracket.

–  To do this, remove lock washers -A- for damping. –  Pull off damping.

–  Push damping upwards in area of upper securing nut -1- above clutch pedal -A- in -direction of arrow-.

–  Remove securing nuts -1- and -2-. The upper securing nut -1- is accessible between the relay carrier and the steering column trim. –  Remove mounting bracket -3-. Installing Install in the reverse order of removal, observing the following:

Some cars have damping -arrow- on the clutch pedal mounting bracket.   Note t  Renew self-locking nuts. t  Renew hose clips. t  Allocate all components according to → Electronic parts catalogue (ETKA).

The crash bar -1- in front of clutch pedal -2- may be secured in different ways. Attachment with 2 bolts –  Install crash bar -1- and tighten 2 bolts to specified torque.

Attachment with 1 bolt –  Install crash bar -1- and tighten bolt -2- to specified torque. –  Install trim and cover below trim on drive side → General body repairs, interior; Rep. gr.68.

–  Push pipe/hose line or plastic line -1- with seal -2- onto connection of master cylinder -4- until securing clip -3- engages audibly. –  Test line by tugging on it. –  After removing hose clamp -3094-, return supply hose to its original position, if necessary. –  Bleed clutch system → Chapter. LHD –  Install battery → Electrical system; Rep. gr.27. Specified torques

Component	Nm
Mounting bracket to bulkhead t  Renew self-locking nuts.	25
Crash bar to steering column mounting bracket (attachment with 2 bolts)	10
Crash bar to steering column mounting bracket (attachment with 1 bolt)	20
t  Renew bolts for crash bar