Volkswagen Golf Variant / Jetta. Manual - part 218

 

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Volkswagen Golf Variant / Jetta. Manual - part 218

 

 

❑ For the plastic hose
❑ The seals must be in‐

side the hose.

3 - Hose

❑ Made of plastic. Refer to

⇒ Fig. ““Plastic

Hose -1- ”“ , page 46

❑ May also be made of

rubber

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 line, remove the clip

up to the stop

❑ 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 - Bracket

❑ Attached to the body
❑ covered by the assembly mounting

11 - Line

❑ The pipe line and pipe/hose line -item 13- 

⇒ Item 13 (page 48)

 may also be a single piece.

❑ Removing and installing. Refer to

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

 .

❑ Allocation. Refer to the Parts Catalog.

1. Clutch Mechanism, Servicing    

47

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 th

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A

G.

Battery, Removing and Installing .

12 - 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.

13 - Hose/Line Assembly

❑ The pipe line and pipe/hose line -item 11- 

⇒ Item 11 (page 47)

 may also be a single piece.

❑ Removing and installing. Refer to

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

 .

Battery, Removing and Installing .

14 - Bracket

❑ Attached to the body

15 - Seal/O-Ring

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

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

❑ Allocation. Refer to the Parts Catalog.

16 - Clamp

❑ To remove and install the hose/line assembly or 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 - Bleeder

❑ Removing and installing. Refer to

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

 .

20 - Seal/O-Ring

❑ Install on the line connection
❑ Install with brake fluid
❑ Seals/O-rings suitable for the line connection material

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

❑ Allocation. Refer to the Parts Catalog.

21 - 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

 .

22 - Transmission

1.10

Clutch Mechanism, Bleeding

Special tools and workshop equipment required
♦ Brake Charger/Bleeder Unit - VAS5234-

48

It is not necessary to pre-fill the system.

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

Filter; Air Filter Housing, Removing and Installing .

– Connect the Brake Charger/Bleeder Unit - VAS5234- .
It is necessary to use the Bleeder Hose (670 mm) - VAG1238/B3-

to bleed.
– Connect the bleeder hose to the brake bleeder unit collector

bottle.

– Connect bleeder hose -A- to bleeder -arrow-.
– Apply 2.0 bar (29 psi) pressure to the system.
– Open the breather valve approximately 1/4 to 1/2 turn.
– Move the clutch pedal 15 to 20 times rapidly by hand from stop

to stop.

– Close breather valve and switch bleeder device off.
– After completing the bleeding procedure, and the pressure has

dropped from 2.0 bar (29 psi), operate the clutch pedal an ad‐

ditional 10 times by foot.

– If it was removed earlier install the complete air filter housing.

Filter; Air Filter Housing, Removing and Installing .

1. Clutch Mechanism, Servicing    

49

Clutch Release Mechanism, Servic‐

ing

⇒ “2.1 Line Assembly and Bleeder on the Clutch Slave Cylinder,

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

and Installing”, page 52
⇒ “2.3 Hose/Line Assembly or Pipe, Removing and Installing”,

page 53
⇒ “2.4 Input Shaft Seal, Replacing”, page 55

Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm - VAG1331-

1 - Transmission
2 - Input Shaft Seal

❑ Replacing. Refer to

⇒ “2.4 Input Shaft Seal,

Replacing”, page 55

 .

3 - Clutch Slave Cylinder with

Release Bearing

❑ Must be replaced to‐

gether because they are

a single unit

❑ Do not wash the bear‐

ing, just wipe it off.

❑ Replace any loud bear‐

ings together with the

clutch slave cylinder

❑ Some clutch slave cylin‐

ders have a divided feed

line. Refer to

⇒ Fig. ““Clutch Slave

Cylinder -A- with Divi‐

ded Supply Line”“ , page

51

❑ Removing and instal‐

ling. Refer to

⇒ “2.2 Clutch Slave Cyl‐

inder with Release

Bearing, Removing and

Installing”, page 52

 .

❑ Approximately from

05/2011: release bear‐

ing with an additional

plastic washer. Refer to

⇒ Fig. ““Approximately

from 05/2011: Release

Bearing with an Addi‐

tional Plastic Washer”“ ,

page 51

 , pressure

plate is adapted

⇒ Fig. ““Only for Release Bearing with Additional Plastic Washer: Pressure Plate Diaphragm Spring

(-arrows-) with A Slightly Lower Installation Height.”“ , page 51

❑ Allocation. Refer to the Parts Catalog.

4 - Bolt

❑ Quantity: 3
❑ Replace after removing

50

 

 

 

 

 

 

 

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