Audi Workshop Service and Repair Manuals

Removing and installing master cylinder Special tools and workshop equipment required

t  Pliers -T10005-

Removing –  If fitted, remove cover panel (front left) -arrows-.

–  If fitted, detach hose -1- for secondary air pump. –  Detach air intake hose at air mass meter -G70- (slacken hose clip -2-). –  Unplug electrical connector for air mass meter -G70--3-. –  Remove bolts -4- and -5- and detach air cleaner housing → Repair group 23 or → Repair group 24.

–  Clamp off supply hose -A- coming from brake fluid reservoir using hose clamp -3094-. –  Disconnect supply hose -A- at master cylinder. –  Remove retaining clip -B- from master cylinder. –  Pull pipe/hose assembly -C- out of master cylinder and seal end of pipe.   Note In order to take out the master cylinder the entire clutch pedal assembly must be removed. –  Remove driver's storage compartment (bottom) → Rep. Gr.68. –  If fitted, remove clutch pedal switch -F36- → Chapter „Removing and installing clutch pedal switch -F36- (square housing)“ or → Chapter „Removing and installing clutch pedal switch -F36- (round housing)“.

–  Now remove complete clutch pedal mounting bracket as follows: –  First remove connecting plate -arrow A--arrows 1-. –  Then remove securing nuts -arrows 2- for mounting bracket -arrow B-. –  Take off mounting bracket.

–  Remove over-centre spring using assembly clip -T10111- as follows: 1 -  The rear part of assembly clip must be positioned on the over-centre spring so that the claws fit exactly over the rib -1-. 2 -  Lightly depress clutch pedal towards clutch pedal stop. –  Engage the lug -2- of the assembly clip into the cut-out on the over-centre spring.

Release master cylinder operating rod from clutch pedal as follows: –  Carefully pull clutch pedal towards you. At the same time, press both sides of retaining clip inwards using pliers -T10005--arrows-.

–  Turn stop -A- for clutch pedal in direction of arrow and remove.

–  Then push master cylinder in the direction of -arrow 1- onto stop. It must not be covered in upper area by over-centre spring mounting -arrow 2-. –  Then swing master cylinder in direction of -arrow 3- out of mounting bracket. Installing Installation is carried out in reverse sequence; note the following:

–  Retaining clip -A- must be fitted on operating rod -B- of master cylinder. –  Press clutch pedal in -direction of arrow- until it engages. Ensure that it is properly locked. –  Install over-centre spring → Chapter or → Chapter.

–  Fit stop -A- for clutch pedal again. Installation position: The arm -arrow- points towards master cylinder -B-. –  Bleed clutch system after installing master cylinder → Chapter. –  If fitted, install clutch pedal switch -F36- in mounting hole → Chapter „Removing and installing clutch pedal switch -F36- (square housing)“ or → Chapter „Removing and installing clutch pedal switch -F36- (round housing)“. –  Install complete air cleaner housing → Repair group 23 or → Repair group 24.