Volkswagen Workshop Service and Repair Manuals

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

• ◆ T10005 Pliers

• ◆ V.A.G 1331 Torque wrench

Removing

• ‒ First check whether a coded radio is fitted. If this is the case obtain the anti-theft coding.
• ‒ With the ignition switched off disconnect the battery earth strap.
• ‒ Remove air cleaner.

=> Repair group 24; Servicing injection system; Removing and installing parts of injection system

• ‒ Remove ABS control unit and hydraulic unit.

=> Brake systems; Repair group 45; Hydraulic unit

• ‒ Pull off supply hose -A- to brake fluid reservoir and seal.
• ‒ → Lever clip -B- for pipe/hose assembly out from master cylinder (direction of arrow).
• ‒ Pull pipe/hose assembly -C- out from master cylinder and seal.

• ‒ Remove driver's side lower cover

=> General body repairs, interior; Repair group 70; Dash panel; Removing and installing dash panel

• ‒ Turn clutch pedal switch 45° anti-clockwise and pull out of mounting.

→ Separate master cylinder operating rod from clutch pedal as follows:

• ‒ Pull clutch pedal lightly towards passenger compartment.
• ‒ Press both sides of mounting inwards using tongs T10005 (arrows).

• ‒ → Now remove complete clutch pedal mounting bracket as follows:
• ‒ Remove connecting plate -A- first (arrows 1).
• ‒ Then remove securing nuts (arrows 2) for mounting bracket -B-.
• ‒ Take off mounting bracket.

• ‒ → Turn stop -A- for clutch pedal in direction of arrow and remove.

• ‒ → Then push master cylinder first in direction of arrow 1 onto stop.

It must not be covered in upper area by over-centre spring mounting (arrow 2).

• ‒ Then swing it in direction of arrow 3 out of mounting bracket.

Installing

Installation is carried out in the reverse sequence, when doing this note the following:

• ‒ → The retainer -A- must be fitted to the master cylinder operating rod -B-.
• ‒ Pull piston rod out of master cylinder slightly and hold using a pair of pliers. Be careful not to damage it when doing this.
• ‒ At the same time, push clutch pedal in direction of arrow to engage. Ensure correct engagement.

• ‒ → Fit stop -A- for clutch pedal again.

Installation position:

The arm (arrow) points towards master cylinder -B-.

• ‒ Bleeding clutch system after installing master cylinder=>page 30-19 .