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Assembly overview - hydraulic system

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Assembly overview - hydraulic system

- Brake fluid reservoir

1

2 - Supply hose

For master cylinder.

3 - Pipe/hose line

Disconnecting from master cylinder and installing Anchor.

Disconnecting from slave cylinder

Fig

Allocation for LHD and RHD vehicles via Electronic parts catalogue (ETKA).

4 - Grommet

5

6 - Clutch pedal

- Mounting bracket

For LHD vehicles

Chapter.

For RHD vehicles

7

Chapter.

- Hexagon socket head bolt, 20 Nm

8 - Pin

Always renew

Lubricate with grease -G 000 450 02-.

9 - Master cylinder

Lubricate with grease -G 000 450 02-. 9 - Master cylinde r  Removing and installing

Removing and installing Chapter

Do not operate clutch pedal after slave cylinder has been removed.

Clip -arrow A- and seal -arrow B- must not be removed.

To remove hose/pipe line, pull out clip -arrow A- only to stop Anchor.

10

11

- Gearbox - Slave cylinder

Do not operate clutch pedal after slave cylinder has been removed.

Brake fluid must not be allowed to get onto gearbox.

Removing and installing Chapter

After working on hydraulic clutch mechanism, bleed clutch system Chapter.

12

- Bleeder valve, 4 Nm

Bleeding clutch system Chapter

13

14

- Dust cap - Clip

Pull clip out to stop to remove pipe/hose line.

15 - Retainer

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Assembly overview - hydraulic system

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For pipe/hose line.

Secured to gearbox with slave cylinder.

16 - Hexagon socket head bolt, 25 Nm

Slave cylinder to gearbox

Self-locking.

Always renew

17 - Hexagon nut, 2 Nm

18 - Seal

Disconnecting slave cylinder from pipe/hose line

Removing

– To remove pipe/hose line, pry out clip -A- to stop using a screwdriver. Only then can you pull out the pipe/hose line.

Installing

– Press in clip -A- to stop.

– Push pipe/hose line -B- into slave cylinder until line audibly engages.

– Test pipe/hose line by tugging on it.

audibly engages. – Test pipe/hose line by tugging on it. vw-wi://rl/V.en-GB.k00508429.wi::25792188.xml?xsl=3 25-Jan-11

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Removing

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Removing

– First check whether a coded radio is fitted. If so, obtain anti-theft code.

– With ignition switched off, disconnect battery earth strap Electrical system; Rep. Gr.27.

– Lay a lint-free cloth in plenum chamber beneath supply hose from brake fluid reservoir.

– Clamp off supply hose -A- to brake fluid reservoir with hose clamp -3094-, pull hose off connecting pipe of master cylinder and seal it.

– Remove grommet for supply hose -A- from bulkhead.

– Pull out clip -C- to stop using screwdriver and then pull out pipe/hose line -B- slightly.

screwdriver and then pull out pipe/hose line -B- slightly. – Remove bolt for brake fluid reservoir

– Remove bolt for brake fluid reservoir -1- and pull off connector for brake fluid level warning contact downwards.

The brake fluid reservoir need not be removed.

downwards. The brake fluid reservoir need not be removed. – Remove vacuum pipe to brake servo

– Remove vacuum pipe to brake servo -1-.

– Unscrew the two Torx bolts -arrows-.

For clarity of illustration, brake fluid reservoir is not shown.

To remove upper Torx bolt, swing brake fluid reservoir slightly to side.

– Remove compartment on driver side General body repairs; Rep. Gr.70.

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Removing

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Release master cylinder operating rod from clutch pedal as follows:

– Insert commercially available needle nose pliers -1- in indentation of clutch pedal.

– Compress mounting -arrow 2-.

– Pull clutch pedal gently into passenger

compartment.

– Pull operating rod and mounting out of clutch pedal

and into engine compartment in -direction of arrow-

.

– Unbolt master cylinder -arrow 1- from inside passenger compartment -arrow 2-.

– Remove securing bolt -arrow 3- for mounting

bracket.

– Pull complete pedal cluster slightly into passenger

compartment.

– Remove master cylinder.

into passenger compartment. – Remove master cylinder. vw-wi://rl/V.en-GB.k00508429.wi::25792202.xml?xsl=3 25-Jan-11
into passenger compartment. – Remove master cylinder. vw-wi://rl/V.en-GB.k00508429.wi::25792202.xml?xsl=3 25-Jan-11

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Removing

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Removing Page 3 of 3 vw-wi://rl/V.en-GB.k00508429.wi::25792202.xml?xsl=3 25-Jan-11

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Installing

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Installing

Installation is performed in the reverse order of removal; when doing this, note the following:

– Insert master cylinder so that seal -1- and washer make contact behind mounting bracket.

– Tighten bolts -2- to specified torque.

– Press connecting pipe -3- with guide -arrow A- into notch -arrow B- on mounting bracket.

guide -arrow A- into notch -arrow B- on mounting bracket. A second mechanic is required for

A second mechanic is required for the next step.

– Push complete pedal cluster forwards to bulkhead and insert bolt -1-.

At the same time, second mechanic must guide pipe/hose line into master cylinder from plenum chamber.

pipe/hose line into master cylinder from plenum chamber. – Tighten securing bolts -arrows- for master brake

– Tighten securing bolts -arrows- for master brake cylinder and brake servo.

– Install vacuum pipe to brake servo -1-.

and brake servo. – Install vacuum pipe to brake servo -1-. vw-wi://rl/V.en-GB.k00508429.wi::25792203.xml?xsl=3 25-Jan-11

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Installing

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– Then tighten securing bolt -1- for brake fluid reservoir.

– Push connector onto brake fluid level warning contact on brake fluid reservoir.

– Press in clip -C- in direction of arrow to stop.

– Push pipe/hose line -B- into master cylinder until line audibly engages.

– Test pipe/hose line by tugging on it.

– Insert grommet -D- for supply hose -A- into bulkhead.

– Push supply hose -A- onto connecting pipe of master cylinder to stop.

– Remove hose clamp -3094-.

– Tighten bolt -1- for securing pedal cluster to dash panel carrier.

Join master cylinder operating rod to clutch pedal as follows:

– The retainer -A- must be fitted to the master cylinder operating rod -arrow-.

be fitted to the master cylinder operating rod -arrow-. vw-wi://rl/V.en-GB.k00508429.wi::25792203.xml?xsl=3 25-Jan-11
be fitted to the master cylinder operating rod -arrow-. vw-wi://rl/V.en-GB.k00508429.wi::25792203.xml?xsl=3 25-Jan-11
be fitted to the master cylinder operating rod -arrow-. vw-wi://rl/V.en-GB.k00508429.wi::25792203.xml?xsl=3 25-Jan-11

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Installing

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– Insert retainer in guide on clutch pedal and push clutch pedal towards bulkhead until it engages, ensuring that it locks properly.

– To ensure that retainer is locked correctly, pull clutch pedal slightly into passenger compartment and push both ends of retainer into clutch pedal using a screwdriver.

– Bleed clutch system after installing master cylinder Chapter.

system after installing master cylinder → Chapter . vw-wi://rl/V.en-GB.k00508429.wi::25792203.xml?xsl=3 25-Jan-11

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