Volkswagen Golf Variant / Jetta. Manual - part 216

 

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Volkswagen Golf Variant / Jetta. Manual - part 216

 

 

of the clutch pedal -2-.
Securing with Two Bolts
– Install the crash bolster -1- and tighten the 2 bolts to the tight‐

ening specification. Refer to

⇒ “1.5.1 Tightening Specifications”, page 40

 .

Securing with One Bolt
– Install the crash bolster -1- and tighten the bolt -2- to the tight‐

ening specification. Refer to

⇒ “1.5.1 Tightening Specifications”, page 40

 .

Continuation for All

– Attach the cable guide -2- to the steering column.
– Install the footwell vents -3-. Refer to ⇒  Heating, Ventilation

Removing, Jetta from MY 2011 .

Vehicles with Knee Airbag
– Install the knee airbag bracket and the impact bolster. Refer

to ⇒  Body Interior ; Rep. Gr.  69 .

Continuation for All
– Install the trim and the cover under the trim on the driver side.

and Covers; Steering Column Trim Panel, Removing and In‐

stalling .

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

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

-3- audibly engages.

– Pull on the line to make sure it is secure.
– 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. Clutch Mechanism, Servicing    

39

Tightening Specifications

Component

Nm

Mounting bracket to bulkhead

♦ Replace the self-locking nuts.

25

Impact bolster to mounting bracket/steering

column (secured with two bolts)

10

Impact bolster to mounting bracket/steering

column (secured with one bolt)

20

♦ Replace the impact bolster bolts

1.6

Clutch Master Cylinder, Removing and

Installing

Special tools and workshop equipment required
♦ Clutch Pedal Pliers - T10005-
Removing
– Remove the mounting bracket. Refer to

⇒ “1.5 Mounting Bracket, Removing and Installing”, page 35

 .

– Disengage the mount for the clutch master cylinder actuator

rod using the Clutch Pedal Pliers - T10005- .

– Place a spacer -A- between the clutch pedal and the stop and

then push the clutch pedal as far as the spacer.

♦ Length of spacer = approximately 40 mm (1.57 in.) (for exam‐

ple 

1

/2" socket insert)

– Disengage the securing bracket -B- and remove the clutch

master cylinder from the mounting bracket in direction of

-arrow 1 and arrow 2-.

Installing
• Move the clutch pedal up to the stop in its resting position.

40

-1-.

– Place a spacer -A- between the clutch pedal and the stop and

then push the clutch pedal as far as the spacer.

♦ Length of spacer = approximately 40 mm (1.57 in.) (for exam‐

ple 

1

/2" socket insert)

– Install the clutch master cylinder on the mounting bracket in

direction of -arrow 1 and arrow 2-.

– Push the clutch master cylinder actuator rod -1- in direction of

-arrow- until the mount -2- clicks into the place in the clutch

pedal.

– Install the mounting bracket. Refer to

⇒ “1.5 Mounting Bracket, Removing and Installing”, page 35

 .

1.7

Clutch Position Sensor - G476- , Re‐

moving and Installing

Special tools and workshop equipment required
♦ Hose Clamps - Up To 25mm - 3094-
Removing
– First check whether a coded radio is installed. If so, obtain the

anti-theft code.

– Disconnect the battery ground cable. Refer to ⇒  Electrical

Connecting .

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

1. Clutch Mechanism, Servicing    

41

Filter; Air Filter Housing, Removing and Installing .

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

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

stalling .

If a Hose/Line Assembly -1- with a Round Component Is Installed

Directly below the Clutch Master Cylinder, Hose/Line Assembly

Must Be Removed.

Note

While performing the following work, make sure no brake fluid

comes into contact with the longitudinal member or the transmis‐

sion. If it does, clean the area thoroughly.

– Place a lint-free cloth under the clutch master cylinder.

– Clamp off the hose to the clutch master cylinder using Hose

Clamps - Up To 25mm - 3094- .

42

 

 

 

 

 

 

 

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