Special tools and workshop equipment required

• Hose clamps, up to Ø 25 mm - 3094-

• Torque wrenches - V.A.G 1331-

• Sealing tool - T10249-

Removing

• Push driver's seat as far back as possible.
• Move steering wheel up as far as it will go, making use of full range of steering column adjuster.
• If fitted, remove footwell cover on driver side.

Vehicles with knee airbag

• Remove the knee airbag -1- on the driver's side.

Vehicles without knee airbag

• Disconnect battery.

Continued for all vehicles:

• Remove the driver-side footwell outlet vent -1- .

• Remove the diagnosis interface for the data bus - J533- from the bracket -1- .

• Remove bolt -2-, detach crash bar -1- and push to one side.
• If the bracket for parking aid control unit - J446- / park assist steering control unit - J791- is fitted next to the clutch pedal, remove bracket . Do not disconnect wiring connections.
• Remove complete air filter housing if it prevents access to the lines for clutch mechanism.

RHD

• An insulation mat is installed in conjunction with some engines.

  Appearance may be different from that illustrated.

• Remove insulation mat. Note item -1...4-.

Left-hand drive vehicles

• Remove battery and battery tray .

Continued for all vehicles:

• Using hose clamp - 3094- , clamp off supply hose -2- to clutch master cylinder.

Note

• Clamping off the supply hose with the hose clamp - 3094- will cause a permanent deformation.
• However, this does not damage the supply hose.
• After removing the hose clamp - 3094- , the supply hose must be returned to its original shape.

• Pull clip for pipe/hose line -1- all the way out and remove pipe/ hose line.
• Seal openings.
• Disconnect supply hose from clutch master cylinder and plug hose using sealing tool - T10249/1- .

Note When working in the footwell, protect the floor covering with cloths from escaping brake fluid.

• Unplug electrical connector -2- at clutch position sender - G476- .
• Remove nuts -arrows- and detach mounting bracket -1-.

Installing

Carry out installation in the reverse sequence, noting the following:

• Renew self-locking nuts and seal for clutch master cylinder after removing.
• If the bracket for parking aid control unit - J446- / park assist steering control unit - J791- is fitted next to the clutch pedal, remove bracket . Do not disconnect wiring connections.
• Position the crash bar -1- and tighten the screw -2- .
• Remove the diagnosis interface for the data bus - J533- from the bracket.
• Install the driver-side footwell outlet vent .

Vehicles with knee airbag

• Install driver-side knee airbag.

Note The battery is installed and connected at a later stage.

Continued for all vehicles:

• Connect pipe/hose assembly -1- to connection.
• Connect supply hose -2- at clutch master cylinder.
• After removing the hose clamp - 3094- , the supply hose must be returned to its original shape.

RHD

• If present, attach the insulation mat in the order -1, 2, 3- around the lines.
• Secure the insulation mat with the lock washer -4-.

Continued for all vehicles:

• Bleeding clutch mechanism.

Vehicles with knee airbag

• Install and connect battery .

Vehicles without knee airbag

• Install and/or connect battery .

Specified torques

• For securing mounting bracket to bulkhead.

Removing and installing master cylinder

Removing

Note

• Carry out Guided fault finding using - Vehicle diagnostic tester before you renew the clutch master cylinder with an assumed fault.
• When working in the footwell, protect the floor covering with cloths from escaping brake fluid.

• Remove mounting bracket
• Remove clutch position sender - G476
• Release catches -arrows- and press out pivot pin -2-
• Detach clutch master cylinder -1-.

Installing

Carry out installation in the reverse sequence, noting the following:

Renew pivot pin after removal.

• Install mounting bracket .
• Install clutch position sender - G476.