Audi Workshop Service and Repair Manuals

Special tools, testers and other items required

• ◆ Hose clamp 3094

Removing

• ‒ If fitted, detach cover over plenum chamber.

• ‒ Disconnect battery earth strap with ignition switched off.
• ‒ Remove electronics box from plenum chamber as follows:

Old version with assembly hole in cowl panel grille:

• ‒ → Screw out bolts -arrows- and pull off cap.

New version with no assembly hole in cowl panel grille:

• ‒ → Pull off clip -1- and lift cowl panel grille -A- slightly. Then screw out bolt -arrow 2-.
• ‒ Screw out remaining bolts -arrows- and pull off cap.

All models:

• ‒ Remove engine control unit and, if applicable, auxiliary relay carrier and auxiliary fuse box.

=> Electrical System; Repair Group 97; Removing and installing auxiliary relay carrier with auxiliary fuse box

• ‒ Unplug connector at connector point.
• ‒ Pull engine wiring harness together with rubber grommet out of recess in electronics box.

• ‒ → Unscrew both nuts -A-.
• ‒ Lift rear of electronics box off studs and then pull out of attachment point -B-.

Notes:

• ◆ Make sure brake fluid does not ingress into plenum chamber or onto gearbox below when performing the following operations. If it does, area affected must be thoroughly cleaned.
• ◆ When working in footwell, cover carpet with cloths to protect it against brake fluid spillage.

Old version with aluminium master cylinder:

• ‒ → Use special tool 3094 to pinch off supply hose -A- to brake fluid reservoir, disconnect at master cylinder and seal off.
• ‒ Remove rubber grommet over connecting pipe for supply hose from bulkhead.
• ‒ Unscrew pipe -B- from master cylinder and seal off.

New version with plastic master cylinder:

• ‒ → Use special tool 3094 to pinch off supply hose -A- to brake fluid reservoir, disconnect at master cylinder and seal off.
• ‒ Remove rubber grommet over connecting pipe for supply hose from bulkhead.
• ‒ Use screwdriver to prise out clip -C- and then pull pipe -B- out slightly.

All models:

• ‒ → Screw out the two Torx socket-head bolts -arrows-.

• ‒ Remove driver's storage compartment.

=> General Body Repairs; Repair Group 68; Storage compartments/covers and trim panels; Removing driver's storage compartment

• ‒ → Separate clutch pedal from master cylinder. To do so, use screwdriver to prise out pin locking element -arrow 1-, pull out pin -arrow 2- and press out clutch pedal.

Note:

• ◆ → When performing the operations described below, make sure clutch pedal does not press clutch pedal switch -1- out of clip, as otherwise switch thread would be damaged and switch would have to be replaced.
• ◆ Switch is only to be fitted once so as to ensure a firm fit.

• ‒ Screw out bolts for master cylinder -arrow 2- and mounting bracket -arrow 3-.
• ‒ Pull entire pedal cluster slightly towards passenger compartment and take out clutch master cylinder -4-.

Installing

Install in reverse order, paying attention to the following:

Aluminium master cylinder with adjustable push rod joint only:

• ‒ → On replacing master cylinder, check dimension -a- at push rod joint when extended and adjust if necessary.
• ‒ LHD vehicles: Dimension a = 165 ± 0.5 mm
• ‒ RHD vehicles: Dimension a = 139 ± 0.5 mm

All models:

• ‒ → Insert master cylinder such that gasket -1- makes contact with washer behind mounting bracket and tighten bolts -2- to 20 Nm.
• ‒ Press connecting pipe -3- with guide -arrow A- into recess -arrow B- at mounting bracket.

A second mechanic is required for the next operation.

• ‒ → Move entire pedal cluster forwards towards bulkhead, insert bolt
  -arrow 3- and hand-tighten. In doing so, have second mechanic guide pipe into master cylinder from plenum chamber.

• ‒ → Tighten bolts for brake servo -arrows- to 25 Nm.

Old version with aluminium master cylinder:

• ‒ → Screw (15 Nm) pipe connecting nut -B- to master cylinder.
• ‒ Insert rubber grommet over connecting pipe for supply hose -A- in bulkhead.
• ‒ Slip on supply hose -A- to brake fluid reservoir as far as it will go.
• ‒ Remove special tool 3094.

New version with plastic master cylinder:

• ‒ → Press home clip -C-.
• ‒ Insert pipe -B- in master cylinder until it is heard to engage.
• ‒ Insert rubber grommet -D- over connecting pipe for supply hose -A- in bulkhead.
• ‒ Slip on supply hose -A- to brake fluid reservoir as far as it will go.
• ‒ Remove special tool 3094.

All models:

• ‒ → Tighten hexagon socket-head bolt -arrow- for securing pedal cluster to dash panel mount to 25 Nm.
• ‒ Connect master cylinder to clutch pedal. Engage pin locking element in clutch pedal.
• ‒ After installing master cylinder, bleed clutch system .

• ‒ → Check setting of clutch pedal switch -1- over clutch pedal as follows:
• ‒ Switch -1- must make full contact with clutch pedal -3- and be fully actuated.
• ‒ Adjustment tolerance: Gap width -a- between clip and mounting bracket -2-/gap width -b- at switch -1- must not exceed 0.7 mm.
• ‒ To adjust, hold clip and turn clutch pedal switch -1-.

Note:

Switch is only to be fitted once so as to ensure a firm fit.

• ‒ Install driver's storage compartment.

=> General Body Repairs; Repair Group 68; Storage compartments/covers and trim panels; Removing driver's storage compartment

• ‒ → Always replace gasket -C-.
• ‒ Make sure gasket does not conceal opening in body and raised metal edge.
• ‒ Insert electronics box at attachment point -B- and tighten nuts -A- to 4 Nm.
• ‒ Press on cap hand-tight and tighten bolts diagonally to 4 Nm (refer also to marking on cap).
• ‒ Lay engine wiring harness and plug in connector in connector point.
• ‒ Install engine control unit and, if applicable, auxiliary relay carrier and auxiliary fuse box.

=> Electrical System; Repair Group 97; Removing and installing auxiliary relay carrier with auxiliary fuse box