Volkswagen Workshop Service and Repair Manuals

Removing and installing over-centre spring, Golf 2004 ► Special tools and workshop equipment required

t  Release tool -T10178-

t  Torque wrench -V.A.G 1331- Removing –  Push driver seat as far back as possible and put steering wheel in highest position. –  Remove trim and cover below trim on driver side → Rep. gr.68.

–  Remove trim and cover below trim on drive side → General body repairs, interior; Rep. gr.68. –  Remove cable guide -2- from steering column. –  Remove footwell vent -3-. → Heating, air conditioning; Rep. gr.80

The crash bar -1- in front of clutch pedal -2- may be secured in different ways. Attachment with 2 bolts –  Remove crash bar -1- (2 bolts).

Attachment with 1 bolt –  Remove crash bar -1- (1 bolt -2-).

If fitted, remove damping -arrow- from lower area of clutch pedal mounting bracket.

–  To do this, remove lock washers -A- for damping. –  Pull off damping.

–  Push damping upwards in area of upper securing nut -1- above clutch pedal -A- in -direction of arrow-.

–  Unbolt clutch pedal -1- from mounting bracket -3- by removing nut -2- and pulling out bolt -5-.   Note The clutch pedal remains hooked to operating rod of master cylinder. –  Swing clutch pedal down slightly and remove over-centre spring -4- from mounting bracket.

Installing   Note Renew self-locking nuts. –  Insert over-centre spring -2- in mounting bracket from above while holding end of spring with assembly tool -T10178- in installation position.

–  Receptacle -arrow- for tip -A- of clutch pedal must stand vertically. –  Insert tip of clutch pedal -1- in bearing recess of over-centre spring. –  Depress clutch pedal slightly, push bolt through and tighten self-locking nut to specified torque.

Some cars have damping -arrow- on the clutch pedal mounting bracket. –  Return it to installation position.

The crash bar -1- in front of clutch pedal -2- may be secured in different ways. Attachment with 2 bolts –  Install crash bar -1- and tighten 2 bolts to specified torque.

Attachment with 1 bolt –  Install crash bar -1- and tighten bolt -2- to specified torque. –  Install trim and cover below trim on drive side → General body repairs, interior; Rep. gr.68. Specified torques

Component	Nm
Clutch pedal to mounting bracket t  Renew self-locking nuts	25
Crash bar to steering column mounting bracket (attachment with 2 bolts)	10
Crash bar to steering column mounting bracket (attachment with 1 bolt)	20
t  Renew bolts for crash bar