Audi Workshop Service and Repair Manuals

Removing and installing clutch master cylinder Special tools and workshop equipment required

t  Hose clamps, up to 25 mm -3094-

t  Open ring spanner, 32 mm -3355- Removing –  Observe notes on removing and installing clutch master cylinder and slave cylinder → Chapter.   Caution Risk of damage to electronic components. Observe the correct procedure for disconnecting the battery.

–  Disconnect earth wire -2- from battery terminal → Rep. gr.27.

–  Detach seal -arrow-. –  Remove left section -3- or complete plenum chamber cover (depending on version) → Rep. gr.50.

–  Remove electronics box in engine compartment → Rep. gr.97.   Note

In the following steps make sure that no brake fluid escapes into the plenum chamber or onto the gearbox below. If this does happen, clean the affected area thoroughly. –  Clamp off supply hose -2- from brake fluid reservoir using hose clamp -3094-. Disconnect hose from clutch master cylinder -1- and plug hose. –  Release retaining clip -3- using a screwdriver and pull out to limit stop. –  Pull off pipe/hose assembly -4-.   Note Leave connector -item 5- connected.

–  Remove over-centre spring -2- → Chapter.

–  Pull locking pin -1- out of clutch pedal -3-.   Note -Item 2- and -arrows A, B- can be disregarded.

–  Release clutch master cylinder in direction of -arrow- using open ring spanner, 32 mm -3355-.

–  Pull out clutch master cylinder -1- and guide it out through opening for engine wiring harness. –  Release connector -5- and unplug. Installing Installation is carried out in reverse sequence; note the following: –  Plug in connector -5-. –  Install clutch master cylinder -1-.

–  Pull clutch master cylinder into footwell in direction of -arrow A-. At the same time lock clutch master cylinder in direction of -arrow B- using open ring spanner, 32 mm -3355-.

–  Insert locking pin -4-. Shoulder on pin -arrow B- must be introduced into groove on clutch pedal.   Note -Items 1, 2, 3- and -arrow A- can be disregarded. –  Install over-centre spring → Anchor.

–  Press in retaining clip -3- as far as stop.   Note If damaged, renew O-ring for pipe/hose assembly -4-. –  Insert pipe/hose assembly -4- into clutch master cylinder and make sure that it engages audibly. –  Pull on pipe/hose assembly to check it is secure. –  Slide on supply hose -2- as far as stop. –  Remove hose clamp, up to 25 mm -3094-. –  Bleed clutch system → Chapter. –  Install electronics box in engine compartment → Rep. gr.97. –  Install plenum chamber cover → Rep. gr.50. –  Follow steps required after connecting battery → Electrical system; Rep. gr.27.