Volkswagen Golf Variant / Jetta. Manual - part 504

 

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Volkswagen Golf Variant / Jetta. Manual - part 504

 

 

push the clutch pedal down as far as the spacer.

♦ Spacer length = approximately 40 mm (for example, 

1

/2 socket

insert)

– Unlock the securing clip -B- and remove the clutch master cyl‐

inder from the mounting bracket -arrow 1 and arrow 2-.

2.6.2

Installing

• Move the clutch pedal into its rest position.
– Attach the mount -2- to the clutch master cylinder actuator rod

-1-.

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

push the clutch pedal down as far as the spacer.

♦ Spacer length = approximately 40 mm (for example, 

1

/2 socket

insert)

– Lock the clutch master cylinder to the mounting bracket

-arrow 1 and arrow 2-.

32

-arrow- until the mount -2- audibly engages inside the clutch

pedal.

– Install the mounting bracket. Refer to

⇒ “2.5 Mounting Bracket, Removing and Installing”, page 26

 .

2.7

Clutch Position Sensor - G476- , Re‐

moving and Installing

⇒ “2.7.1 Removing”, page 33
⇒ “2.7.2 Installing”, page 34

2.7.1

Removing

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

anti-theft code.

Disconnect the battery ground cable. Refer to ⇒  Electrical Equip‐

ment; Rep. Gr.  27 ; Battery; Battery, Disconnecting and Con‐

necting .
– Remove the entire air filter housing if it is located near the bat‐

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

Be careful not to get any brake fluid on the longitudinal member

or on the transmission when performing the following work. If it

does, clean the areas thoroughly.

2. Clutch Mechanism, Servicing    

33

Hose Clamps - Up To 25mm - 3094- .

– Disengage the clamp -2- using a screwdriver or a pointed tool

and pull the clutch master cylinder out until it stops.

– Disconnect the hose/line assembly -1- or plastic line from the

clutch master cylinder and seal it.

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

master cylinder -arrow- and remove it.

2.7.2

Installing

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

Note

Allocate all components according to the Parts Catalog.

34

on the master cylinder connection -4- until clip -3- audibly

engages.

– Pull on the hose/line assembly or plastic line to make sure it

is secure.

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

the hose back to its original shape if necessary.

– Bleed the clutch mechanism. Refer to

⇒ “3 Clutch Mechanism, Bleeding”, page 42

 .

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

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

stalling .

– If removed, install the complete air filter housing. Refer to ⇒ 

Rep. Gr.  24 ; Air Filter; Air Filter Housing, Removing and In‐

stalling .

– Connect the battery and follow the procedure regarding what

to do after connecting a battery. Refer to ⇒  Electrical Equip‐

ment; Rep. Gr.  27 ; Battery; Battery, Disconnecting and

Connecting .

2.8

Overview - Hydraulics

1 - Brake Fluid Reservoir
2 - Spring Clamp

❑ Not available

3 - Hose

❑ Made of plastic. Refer to

⇒ Fig. ““Plastic hose -1-

”“ , page 37

4 - Clutch Master Cylinder

❑ Removing and instal‐

ling. Refer to

⇒ “2.6 Clutch Master

Cylinder, Removing and

Installing”, page 31

 .

5 - Clamp

❑ To remove and install

line between the clutch

master and slave cylin‐

der, pull clip out as far as

stop.

❑ On some clutch master

cylinders, it is pulled out

on the side

6 - Support

❑ To remove and install,

disconnect the clutch

master cylinder from the

clutch pedal. Refer to

⇒ “2.4 Clutch Pedal, Re‐

moving and Installing”,

page 21

 .

7 - Clutch Pedal

❑ Removing and instal‐

ling. Refer to

2. Clutch Mechanism, Servicing    

35

 

 

 

 

 

 

 

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