Volkswagen Golf Variant / Jetta. Manual - part 217

and pull the clutch master cylinder out until it stops.

– Remove the hose/line assembly -1- and the pipe from the

clutch master cylinder and seal it off.

– Disconnect the connector -4-.
– Unclip the Clutch Position Sensor - G476- from the clutch

master cylinder -arrow- and remove it.

Note

Ignore item -3-.

Installing
Install in reverse order of removal while. Note the following:

Note

♦

Replace the hose clamps

♦

Allocate all components according to the Parts Catalog.

If the Hose/Line Assembly was Removed

– Install the hose/line assembly -1- and the pipe line with the

seal -2- on the clutch master cylinder connection -4- until the

clip -3- audibly engages.

– Pull on the hose/line assembly and pipe to make sure it is se‐

cure.

– After removing the Hose Clamps - Up To 25mm - 3094- , bring

the return hose back to its original shape.

– Bleed the clutch mechanism. Refer to

⇒ “1.10 Clutch Mechanism, Bleeding”, page 48

 .

– Install the battery tray and the battery. Refer to ⇒  Electrical

Equipment; Rep. Gr.  27 ; Battery; Battery, Removing and In‐

stalling .

– Install entire air filter housing if it is located near the battery.

Filter; Air Filter Housing, Removing and Installing .

– Connect the battery and follow the steps for after connecting

the battery. Refer to ⇒  Electrical Equipment; Rep. Gr.  27 ;

Battery; Battery, Disconnecting and Connecting .

1.8

Overview - Hydraulics

1. Clutch Mechanism, Servicing    

43

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❑ Not on all vehicles

3 - Hose

❑ Rubber
❑ As of 12.2005, made of

plastic. Refer to

⇒ Fig. ““Plastic

Hose -1- ”“ , page 46

4 - Clutch Master Cylinder

❑ Removing and instal‐

ling. Refer to

⇒ “1.6 Clutch Master

Cylinder, Removing and

Installing”, page 40

 .

5 - Clamp

❑ To remove and install

the hose/line assembly

or pipe, pull the clamp all

the way out.

❑ On some clutch master

cylinders, it is pulled out

on the side

6 - Seal/O-Ring

❑ Install on the line con‐

nection

❑ Install with brake fluid
❑ Seals/O-rings suitable

for the line connection

version. Refer to

⇒ Fig. ““Sealing Rings/

O-Rings for Hose/Line

Assembly or Pipe”“ ,

page 45

❑ Allocation. Refer to the Parts Catalog.

7 - Support

❑ To remove and install, disconnect the clutch master cylinder from the clutch pedal. Refer to

⇒ “1.4 Clutch Pedal, Removing and Installing”, page 29

 .

8 - Clutch Pedal

❑ Removing and installing. Refer to 

⇒ “1.4 Clutch Pedal, Removing and Installing”, page 29

 .

9 - Hex Nut

❑ 25 Nm
❑ Self-locking
❑ Quantity: 3
❑ For the mounting bracket to the bulkhead
❑ Replace after removing

10 - Hose/Line Assembly

Battery, Removing and Installing .

❑ Removing and installing. Refer to

⇒ “2.3 Hose/Line Assembly or Pipe, Removing and Installing”, page 53

 .

11 - Bracket

❑ For hose/line assembly -item 10- 

⇒ Item 10 (page 44)

44

⇒ Fig. ““Bracket Differentiation”“ , page 46

12 - Line

Battery, Removing and Installing .

❑ Removing and installing. Refer to

⇒ “2.3 Hose/Line Assembly or Pipe, Removing and Installing”, page 53

 .

13 - Bracket

❑ For the pipe -item 12- 

⇒ Item 12 (page 45)

❑ Attached to the body
❑ Covered by the assembly mounting
❑ Bracket differentiation. Refer to 

⇒ Fig. ““Bracket Differentiation”“ , page 46

14 - Seal/O-Ring

❑ Install on the line connection
❑ Install with brake fluid
❑ Seals/O-rings suitable for the line connection version. Refer to

⇒ Fig. ““Sealing Rings/O-Rings for Hose/Line Assembly or Pipe”“ , page 45

❑ Allocation. Refer to the Parts Catalog.

15 - Bleeder

❑ Removing and installing. Refer to

⇒ “2.1 Line Assembly and Bleeder on the Clutch Slave Cylinder, Removing and Installing”, page 52

 .

16 - Clamp

❑ To remove and install the hose/line assembly or pipe and the bleeder, pull the clip all the way out.

17 - Breather Valve

❑ Bleed clutch mechanism. Refer to 

⇒ “1.10 Clutch Mechanism, Bleeding”, page 48

 .

18 - Dust Cap
19 - Clutch Slave Cylinder

❑ The gasket can only be replaced when the transmission is removed.
❑ Removing and installing. Refer to

⇒ “2.2 Clutch Slave Cylinder with Release Bearing, Removing and Installing”, page 52

 .

20 - Transmission

Sealing Rings/O-Rings for Hose/Line Assembly or Pipe

Item

Line Connection Version

1

Line connection with a groove all the way around

-arrow 1-

2

Line connection with a shoulder -arrow 2-

3

Line connection with a shoulder -arrow 2- and with

a groove all the way around -arrow 3-

1. Clutch Mechanism, Servicing    

45

Bracket Differentiation

Dimension “a” mm

Line Version

8

Line

6

Hose/Line Assembly

1.9

Overview - Hydraulics, RHD

46