SEAT Workshop Service and Repair Manuals

Remove and install bearing bracket and master cylinder Observe the notes on removing and installing clutch master cylinder → Chapter Check the tool and equipment equivalence table according to the applicability between Seat / VW / Audi / Skoda → Chapter Special tools and workshop equipment required

t  Hose clamps -3094-, see equivalent → Anchor

t  Pliers -V.A.G 1922- Removal:   Caution Follow steps required when disconnecting battery → Electrical system; Rep. gr. 27. –  With the ignition switched off, disconnect battery earth strap → Electrical system; Rep. gr. 27.

–  Use screwdriver to pry off the two caps -3-. –  Unscrew nuts -4- and detach the two wiper arms -2-. –  Pull off clips -1- and detach cowl panel grille -5-.

Take the electronics box out of the plenum chamber as follows: –  Unscrew bolts -arrows- and take off the cover.

–  Use screwdriver to carefully pry off retaining strap -arrow-. –  Lay aside engine control unit with connectors attached.

–  Unplug connectors -2- at connector console. –  Unscrew electrical line connector -1-.

–  Release retaining clips -arrows- and lift auxiliary relay carrier out of electronics box. –  Remove engine wiring harness together with rubber grommet from cutout in electronics box.

–  Remove nuts -arrows- and lift out electronics box -1-.   Note t  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. t  When performing work in the footwell, put cloths on the carpet to protect it from possible brake fluid spills.

–  Clamp supply hose -A- from brake fluid reservoir using hose clamp -3094-. Pull hose off master cylinder and plug hose. –  Remove rubber grommet from bulkhead above connection pipe for supply hose. –  Lever out retaining clip -C- using a screwdriver and pull out pipe/hose assembly -B- slightly.

–  Unscrew bolt for brake fluid reservoir -1- and unplug connector for brake fluid level warning contact downwards.   Note The brake fluid reservoir does not have to be removed.

–  Remove vacuum line from brake booster -1-. –  Remove the two Torx bolts -arrows-.   Note t  The brake fluid reservoir is not shown in the figure for better illustration. t  The brake fluid reservoir must be moved slightly to the side in order to unscrew the upper Torx bolt. –  Remove storage compartment on driver's side → General body repairs, interior; Rep. gr. 68. –  Remove over-centre spring → Chapter.

–  Disconnect brake pedal from brake servo → Brake system; Rep. gr.47 .

–  Disconnect steering column from steering box -arrow A- → Running gear, front-wheel drive and four-wheel drive; Rep. gr.48. –  Unplug connectors from clutch pedal switch-1-, brake light switch-2- and accelerator pedal module -3-. –  Unscrew securing bolt for mounting bracket -arrow B- and remove entire pedal cluster.

Release master cylinder operating rod from clutch pedal as follows:   Note t  When releasing the operating rod, make sure that clutch pedal does not collide with mounting bracket for clutch pedal switch -arrow-. While doing this, the mount can break. t  Install clutch pedal switch only once so that the clutch pedal switch -F 36- → Item is seated correctly in the pedal assembly. –  Apply spark plug connector pliers -V.A.G 1922- in clutch pedal recesses, press on sides of retaining clip → Item and detach clutch pedal from clutch master cylinder.

–  Detach retaining clip -1- and remove clutch pedal -2-. –  Unscrew bolts -3- and remove clutch master cylinder -4-. Installation Installation is carried out in reverse order, noting the following:

–  Fit clutch master cylinder -4- and tighten bolts -3- to 20 Nm.

–  Insert mount -1- in clutch pedal. –  Lock clutch pedal in position by pressing in -direction of arrow-. Check whether mount -1- is seated correctly on the clutch pedal.

The aid of a second mechanic is required for the following work. –  Insert entire pedal cluster and tighten bolt -1- by hand. The second mechanic should guide pipe/hose assembly into clutch master cylinder from plenum chamber.

–  Tighten bolts for brake servo -arrows- to 25 Nm.

–  Push retaining clip -A- to stop. –  Insert pipe/hose assembly -B- in clutch master cylinder and make sure that it engages audibly. –  Fit rubber grommet -D- onto connecting pipe for supply hose -A- at bulkhead. –  Push supply hose -A- from brake fluid reservoir on as far as it will go. –  Remove hose clamp -3094-.

–  Screw in securing bolt -1- for brake fluid reservoir and plug in connector at brake fluid level warning contact.

–  Tighten hexagon socket head bolt -arrow B- for securing pedal cluster to dash panel carrier to 25 Nm. –  Plug in connectors -1-, -2- and -3-. –  Connect brake pedal to brake servo → Brake system; Rep. gr.47. –  Secure steering column to steering box -arrow A- → Running gear, front-wheel drive and four-wheel drive; Rep. gr.48. –  Install over-centre spring → . –  Install storage compartment on driver's side → General body repairs, interior; Rep. gr. 68. –  Bleeding clutch system → Chapter

–  Insert electronics box and tighten nuts -arrows- to 4 Nm. –  Route engine wiring harness and connect connector in connection station. –  Install engine control unit → Engine, injection system; Rep. gr.23 or → Rep. gr.24. –  If applicable, install auxiliary relay carrier and auxiliary fuse carrier → Electrical system; Rep. gr. 97. –  Press on cap hand-tight and tighten bolts crosswise to 4 Nm.

–  Fasten cowl vent grille -5- with clips -1-. –  Install both wiper arms -2- and fasten with both nuts -4-. –  Install both caps -3-. –  Take all the necessary precautionary measures when connecting the battery → Electrical system; Rep. gr. 27.