Volkswagen Golf Variant / Jetta. Manual - part 499

 

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Volkswagen Golf Variant / Jetta. Manual - part 499

 

 

Clutch Mechanism, Servicing

⇒ “2.1 Overview - Clutch”, page 12
⇒ “2.2 Overview - Pedal Cluster”, page 14
⇒ “2.3 Over-Center Spring, Removing and Installing”, page 15
⇒ “2.4 Clutch Pedal, Removing and Installing”, page 21
⇒ “2.5 Mounting Bracket, Removing and Installing”, page 26
⇒ “2.6 Clutch Master Cylinder, Removing and Installing”,

page 31
⇒ “2.7  Clutch Position Sensor G476 , Removing and Installing”,

page 33
⇒ “2.8 Overview - Hydraulics ”, page 35
⇒ “2.10 Clutch Slave Cylinder, Removing and Installing”,

page 39

2.1

Overview - Clutch

Note

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

Disconnect the battery ground cable. 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.

12

fer to

⇒ “2.2 Overview - Pedal Clus‐

ter”, page 14

 .

II - Overview Hydraulics, LHD.

Refer to

⇒ “2.8 Overview - Hydraulics ”,

page 35

 .

III - NOT for North American

Market

2. Clutch Mechanism, Servicing    

13

Overview - Pedal Cluster

1 - Bulkhead

❑ With a mount for the

mounting bracket

2 - Seal

❑ Replace after removing
❑ 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 15

❑ Removing and instal‐

ling. Refer to

⇒ “2.5 Mounting Brack‐

et, Removing and Instal‐

ling”, page 26

 .

4 - Bolt
5 - Over-Center Spring

❑ Removing and instal‐

ling. Refer to

⇒ “2.3 Over-Center

Spring, Removing and

Installing”, page 15

 .

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

❑ Removing and installing. Refer to 

⇒ “2.4 Clutch Pedal, Removing and Installing”, page 21

 .

9 - Support

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

⇒ “2.4 Clutch Pedal, Removing and Installing”, page 21

 .

10 - Seal

❑ Replace after removing
❑ Between the clutch master cylinder and the mounting bracket

11 - Clutch Master Cylinder

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

⇒ “2.6 Clutch Master Cylinder, Removing and Installing”, page 31

12 - Clutch Position Sensor - G476-

❑ Removing and installing. Refer to

⇒ “2.7  Clutch Position Sensor G476 , Removing and Installing”, page 33

 .

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

14

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

14 - Hose

❑ Made of plastic. Refer to 

⇒ Fig. ““Plastic hose -1- ”“ , page 37

15 - Hex Nut

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

16 - Hex Nut

❑ 25 Nm
❑ Replace after removing

17 - Stop

❑ For the clutch pedal

Mounting Bracket with Damper -arrow-

2.3

Over-Center Spring, Removing and In‐

stalling

⇒ “2.3.1 Removing”, page 15
⇒ “2.3.2 Installing”, page 18
⇒ “2.3.3 Tightening Specifications”, page 20

2.3.1

Removing

Special tools and workshop equipment required
♦ Over-Center Spring Assembly Tool - T10178-
♦ Torque Wrench 1331 5-50Nm - VAG1331-

2. Clutch Mechanism, Servicing    

15

 

 

 

 

 

 

 

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