Volkswagen Golf Variant / Jetta. Manual - part 138

 

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Volkswagen Golf Variant / Jetta. Manual - part 138

 

 

1

Clutch Mechanism, Servicing

⇒ “1.1 Overview”, page 14
⇒ “1.1 Overview”, page 14
⇒ “1.3 Over-Center Spring, Removing and Installing”, page 17
⇒ “1.4 Clutch Pedal, Removing and Installing”, page 23
⇒ “1.5 Mounting Bracket, Removing and Installing”, page 28
⇒ “1.6 Clutch Master Cylinder, Removing and Installing”,

page 33
⇒ “1.7  Clutch Position Sensor G476 , Removing and Installing”,

page 35
⇒ “1.8 Overview - Hydraulics”, page 37
⇒ “1.10 Clutch Slave Cylinder, Removing and Installing”,

page 41
⇒ “1.11 Clutch System, Bleeding”, page 44

1.1

Overview

Note

Get the anti-theft code for the radio before disconnecting the battery.

Disconnect the battery ground cable with the ignition switched off. Refer to ⇒  Electrical Equipment; Rep.

Gr.  27 ; Battery; Battery, Disconnecting and Connecting .

Connect battery and follow the procedures to be performed after connecting a battery. Refer to ⇒  Electrical

Equipment; Rep. Gr.  27 ; Battery; Battery, Disconnecting and Connecting .

Lubricate all bearing areas and contact surfaces. Refer to the Parts Catalog for the grease allocation.

14

fer to

⇒ “1.2 Overview - Pedal As‐

sembly”, page 16

 .

II - Overview Hydraulics. Refer

to

⇒ “1.8 Overview - Hydraulics”,

page 37

 .

III - Overview Hydraulics
Not for North American mar‐

ket.

1. Clutch Mechanism, Servicing    

15

Overview - Pedal Assembly

1 - Bulkhead

❑ With a mount for the

mounting bracket

2 - Seal

❑ Always replace.
❑ Between the mounting

bracket and bulkhead

❑ Self-adhesive
❑ Attached to the mount‐

ing bracket

3 - Mounting Bracket

❑ For the clutch pedal

mount

❑ some versions have a

damper. Refer to

⇒ Fig. ““Mounting

Bracket with

Damper -arrow- ”“ ,

page 17

❑ Removing and Instal‐

ling. Refer to

⇒ “1.5 Mounting Brack‐

et, Removing and Instal‐

ling”, page 28

 .

4 - Bolt
5 - Over-Center Spring

❑ Removing and Instal‐

ling. Refer to

⇒ “1.3 Over-Center

Spring, Removing and

Installing”, page 17

 .

6 - Bearing Bushing
7 - Mounting Pin
8 - Clutch Pedal

❑ Removing and Installing. Refer to 

⇒ “1.4 Clutch Pedal, Removing and Installing”, page 23

 .

9 - Support

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

⇒ “1.4 Clutch Pedal, Removing and Installing”, page 23

 .

10 - Seal

❑ Always replace.
❑ Between the clutch master cylinder and the mounting bracket

11 - Clutch Master Cylinder

❑ Removing and installing after removing the mounting bracket. Refer to

⇒ “1.5 Mounting Bracket, Removing and Installing”, page 28

12 - Clutch Position Sensor - G476-

❑ Removing and Installing. Refer to

⇒ “1.7  Clutch Position Sensor G476 , Removing and Installing”, page 35

 .

❑ Can be checked in “Guided Fault Finding” using the Vehicle Diagnostic Tester ⇒ Vehicle diagnostic tester
❑ The Clutch Position Sensor - G476- is called the Clutch Pedal Switch - F36- in “Guided Fault Finding”.

16

❑ The clamp must be removed in order to remove/install the hose/line assembly

14 - Hose

❑ Rubber
❑ Made of plastic from 12/2005. Refer to 

⇒ Fig. ““Plastic Hose -1- ”“ , page 39

15 - Hex Nut, 25 Nm

❑ Self-locking
❑ Quantity: 3
❑ For the mounting bracket to the bulkhead
❑ Always replace.

16 - Hex Nut

❑ 25 Nm
❑ Always replace.

17 - Stop

❑ For the clutch pedal

Mounting Bracket with Damper -arrow-

1.3

Over-Center Spring, Removing and In‐

stalling

⇒ “1.3.1 Removing”, page 17
⇒ “1.3.2 Installing”, page 20
⇒ “1.3.3 Tightening Specifications”, page 22

1.3.1

Removing

Special tools and workshop equipment required
♦ Over-Center Spring Assembly Tool - T10178-

1. Clutch Mechanism, Servicing    

17

 

 

 

 

 

 

 

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