Slave cylinder, removing and installing

WARNING: This page is about a different car, the 2005 Audi A4, 2004 Audi A4, 2003 Audi A4, and 2002 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

Fig 1: Identifying Hose Clamps 3094

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3094 Hose clip

Fig 2: Identifying Spark Plug Connector Pliers V.A.G 1922

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VAG 1922 Pliers

Removing

Remove rubber seal from plenum chamber in direction of arrow.

Fig 3: Removing Cover Over Plenum Chamber

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Remove cover -1- over plenum chamber.
Check whether an encoded radio is installed. If so, obtain anti-theft code.

CAUTION:

On vehicles equipped with Audi Telematics by OnStar ® , switch-off the emergency (back-up) battery for the Telematic/Telephone Control Module prior to disconnecting the vehicle battery. Switch-on the emergency (back-up) battery after reconnecting the vehicle battery. Refer to

91 - COMMUNICATION
91 RADIO, TELEPHONE, NAVIGATION, TRIP COMPUTER for Cabriolet

Disconnect battery ground strap with ignition switched off.

Fig 4: Removing Securing Clips And Cowl

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Use screwdriver to pry off the two caps -3-.
Remove nuts -4- and detach the two wiper arms -2-.
Pull off clips -1- and remove cowl panel grille -5-.

Remove electronics box in plenum chamber as follows:

Fig 5: Electronics Box Sealing Cover

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Screw out bolts -arrows- and pull off sealing cover.

Fig 6: Using Screwdriver To Remove Retainer Bar And Engine Control Module (ECM) J623

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Carefully pry off retainer bar with screwdriver -arrow-.

Fig 7: Releasing Connector Latches And Pulling Off Connectors On Engine Control Module

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Release connector latches -arrows- and pull off connectors -1- and -2- on engine control module.

Fig 8: Connector At Connector Rail And Wire

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Pull off connector -2- from connector rail
Disconnect wire -1-.

Fig 9: Locating Auxiliary Relay Carrier Catches

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Release catches -arrows- and pull auxiliary relay carrier in electronics box upward to remove.
Pull engine wiring harness together with rubber grommet out of recess in electronics box.

Fig 10: Electronics Box Nuts

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Remove nuts -arrows- and lift out electronics box -1-.

NOTE:

Make sure that brake fluid does not escape into the plenum chamber or onto the transmission below. If this does happen, clean the affected areas thoroughly.
Protect the carpet from brake fluid using rags when performing work in the footwell.

Fig 11: Identifying Brake Fluid Reservoir Return Hose Grommet

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Clamp supply hose -A- leading to brake fluid reservoir using special tool 3094. Pull hose off at master cylinder and plug it.
Remove rubber grommet from bulkhead on the supply hose connecting line.
Use a screwdriver to pry out retaining clip -C- and then pull out line -B- slightly.

Fig 12: Location Of Brake Fluid Reservoir Dowel Bolt

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Remove bolt from brake fluid reservoir -1- and disconnect connector from fluid level below.

NOTE: Do not remove the brake fluid reservoir.

NOTE:

For ease of illustration, brake fluid reservoir is not shown.
To remove the top Torx bolt, swivel brake fluid reservoir slightly to one side.

Fig 13: Location Of Brake Servo Securing Bolts

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Remove the two Torx bolts -arrows-.
Remove vacuum line from brake servo -1-.
Remove driver's side storage compartment.

Refer to

68 - INTERIOR EQUIPMENT
68 - INTERIOR EQUIPMENT for Cabriolet

Fig 14: Brake Pedal At Brake Servo

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Detach brake pedal from brake servo.

Refer to 47 - BRAKES - HYDRAULIC COMPONENTS

Fig 15: Locating Steering Column At Steering Gear And Disconnecting Connector On Clutch Pedal Switch, Brake Pedal Switch And On Accelerator Pedal Module

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Disconnect steering column from steering gear -arrow A-.

Refer to 48 - STEERING

Disconnect connector on clutch pedal switch -1-, brake pedal switch -2- and on accelerator pedal module -3-.
Remove securing bolt from mounting bracket -arrow B- and complete pedal cluster.

Release master cylinder operating rod from clutch pedal as follows:

Removing over-center spring. Refer to Over-center spring, removing and installing .

NOTE:

Make sure a tight connection in the clutch pedal switch. Refer to Pedal cluster, assembly overview Pos. 6 as well as the Clutch Pedal Position (CPP) Switch -F194-. Refer to Pedal cluster, assembly overview Pos. 14 in the pedal cluster, these switches may only be installed once.

Fig 16: pressing Retainer Together And Detaching Clutch Pedal From Master Cylinder Using VAG 1922

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When releasing clutch pedal make sure that it does not strike against retainer for clutch pedal switch -arrow-. This could break the retainer.

Insert pliers VAG 1922 into recess of clutch pedal, press retainer together -arrows- and detach clutch pedal from master cylinder.

Fig 17: Identifying Retaining Clip, Clutch Pedal, Bolts And Master Cylinder

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Remove retaining clip -1- and pull off clutch pedal -2-.
Remove bolts -3- and detach master cylinder -4-.

Installing

Install in reverse order, paying attention to the following:

Fig 18: Identifying Retaining Clip, Clutch Pedal, Bolts And Master Cylinder

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Insert master cylinder and tighten screws -3- to 20 Nm.

Fig 19: Locating Mounting Bolts

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Insert retainer -1- into clutch pedal.
Press clutch pedal in direction of arrow to engage, make sure that retainer -1- is correctly locked in clutch pedal.
Install over-center spring. Refer to Over-center spring, removing and installing .

A second mechanic is required for the next step.

Fig 20: Location Of Clutch Pedal Switch F36 And Pedal Assembly Securing Bolt

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Insert complete pedal cluster and install bolt -1- hand-tight. The second mechanic must simultaneously insert line into master cylinder from plenum chamber side.

Fig 21: Location Of Brake Servo Securing Bolts

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Tighten bolts for brake servo -arrows- to 25 Nm.

Fig 22: Installing Rubber Grommet And After-Run Hose

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Press in retaining clip -C- up to stop.
Insert line -B- into master cylinder until it is heard to engage.
Insert rubber grommet -D- over supply hose connecting line -A- into bulkhead.
Slide supply hose -A- for the brake fluid reservoir up to stop.

Remove special tool 3094.
Install bolt for brake fluid reservoir.

Tighten hex socket-head bolt for securing pedal cluster on instrument panel support to 25 Nm.
Plug in connectors.
Connect brake pedal to brake servo.

Refer to 47 - BRAKES - HYDRAULIC COMPONENTS

Secure steering column to steering gear -arrow A-.

Refer to 48 - STEERING

Installing driver's storage compartment:

Refer to

68 - INTERIOR EQUIPMENT
68 - INTERIOR EQUIPMENT for Cabriolet

Bleed clutch system. Refer to Clutch system, bleeding .

Fig 23: Electronics Box Nuts

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Insert electronics box and tighten nuts -arrows- to 4 Nm.
Route engine wiring harness and connect connectors to connector point.
Install engine control module and if applicable auxiliary relay carrier with auxiliary fuse carrier.

Refer to 97 WIRING

Press on sealing cover hand-tight and tighten screws in diagonal sequence to 4 Nm.

NOTE:

On re-connecting battery, remember to check and re-activate vehicle equipment (radio, clock, convenience electronics, etc.).

Refer to

01 - MAINTENANCE
01 - MAINTENANCE for Cabriolet