Assembly overview - pedal cluster

1. - Clutch master cylinder
   • Removing and installing
2. - Mounting bush
   • Removing and installing
   • Cable must not be greased
3. - Clamp
   • To remove pipe, pull out clip to stop.
   • Can be driven in fully before the line is installed
4. - Seal
   • Self-adhesive
   • Renew after removing the clutch master cylinder
   • Glue onto clutch master cylinder
5. - Clutch position sender - G476-
   • Can be checked using - Vehicle diagnostic tester in Guided fault finding mode.
   • Equivalent
   • Removing and installing
6. - Bearing shaft
   • Must be renewed if removed
   • Cable must not be greased
7. - Buffer stop
8. - Hexagon nut
   • For mounting bracket to bulkhead
   • 3 Units
   • Self-locking
   • Must be renewed if removed
   • 25 Nm
9. - Bearing cap
   • 2 Units
   • Installed on both sides
   • Only fitted in conjunction with over-centre spring.
   • Cable must not be greased
10. - Mounting bracket
    • For clutch pedal
    • Removing and installing
    • Using drift - VW 207- drive bushes for the studs used to fasten the mounting bracket onto the bulkhead, into the holes in the mounting bracket
11. - Recovery spring
    • Fitted depending on design status
    • Removing and installing
    • Do not grease seat on mounting bracket
12. - Bearing shaft
    • For clutch master cylinder
    • Must be renewed if removed
    • Cable must not be greased
13. - Over-centre spring
    • Fitted depending on design status
    • Different versions available
    • Removing and installing
    • Cable must not be greased
14. - Mounting bush
    • Cable must not be greased
15. - Sliding bush
    • Fitted depending on design status
    • For mounting return spring
    • Fit onto clutch pedal
    • Grease when mounting return spring.
    • For grease allocation, refer to - Electronic parts catalogue (ETKA) .
16. - Bearing shaft
    • for plunger of the clutch master cylinder
    • Must be renewed if removed
    • Cable must not be greased
17. - Clutch pedal
    • Removing and installing
    • Cable must not be greased
18. - Pedal rubber
19. - Mounting bush
    • Cable must not be greased
20. - Extension spring
    • For clutch pedal
    • Fitted depending on design status
    • Installing and removing - Removing and installing over-centre spring
    • Cable must not be greased
21. - Damping piece
    • Only fitted in conjunction with extension spring.
    • Cable must not be greased

Assembly overview - clutch hydraulics

1. - Hexagonal bolt
   • Tightening torque
2. - Bleeder screw
   • Bleeding clutch mechanism
   • Tightening torque
3. - Dustcap
4. - Supply hose
5. - Brake fluid reservoir
6. - Seals
   • If damaged, renew together with supply hose
   • Must be fitted in supply hose
7. - Clutch master cylinder
   • Removing and installing
8. - Clamp
   • To remove pipe, pull out clip to stop.
   • Can be driven in fully before the line is installed
9. - Seals / O-rings
   • Renew if damaged.
   • Install on line connection
   • Lubricate with brake fluid before installing
   • Whether a seal or an O-ring is used depends on the type of connection
   • Equivalent
10. - Support bracket
    • For pipe/hose assembly
    • Different supports for LHD and RHD vehicles.
    • Equivalent
11. - Hose/metal pipe
    • Different lengths for LHD and RHD vehicles.
    • Equivalent
    • Removing and installing
12. - Seals / O-rings
    • Replace if damaged
    • Install on line connection
    • Lubricate with brake fluid before installing
    • Whether a seal or an O-ring is used depends on the type of connection
    • Equivalent
13. - Clamp
    • To remove pipe, pull out clip to stop.
    • Can be driven in fully before the line is installed
14. - Clutch cylinder:
    • Removing and installing

Assembly overview - clutch release mechanism

1. - Clutch release bearing
   • Remove and install together with clutch release lever and guide sleeve
   • Do not wash out bearing; wipe only
   • Replace collars that make a noise
2. - Bolt
   • Must be renewed if removed
   • 5 Nm + +90º
3. - Clutch release lever
   • Remove and install together with release bearing and guide sleeve
   • Remove any traces of grease
   • Grease contact surface of ball-head pin with grease for clutch plate splines
   • For grease allocation, refer to - Electronic parts catalogue (ETKA) .
4. - Retaining spring
   • Secure to clutch lever
5. - Guide sleeve
   • Remove and install together with release bearing and clutch release lever
6. - Ball head studs
   • For removal and installation the gearbox must be removed
   • Remove any traces of grease
   • Grease contact surface of ball-head pin with grease for clutch plate splines
   • For grease allocation, refer to - Electronic parts catalogue (ETKA) .
   • 20 Nm
7. - Input shaft oil seal:
   • Must be renewed if removed
8. - Gearbox
9. - Hexagonal bolt
   • 20 Nm
10. - Clutch cylinder:
    • Removing and installing