Clutch master cylinder, removing and installing

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2008 Audi S4, 2008 Audi RS 4, 2007 Audi S4, 2007 Audi RS 4, and 2006 Audi S4. 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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Hose clamps, up to Ø 25 mm 3094

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pliers V.A.G 1922

Fig 3: Identifying Plenum Chamber Cover & Removing Rubber Seal

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Removing

CAUTION:

Follow steps required when disconnecting battery →
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for Cabriolet
.
On vehicles equipped with a telematics system, activate the telematics control module service mode before disconnecting the battery →
- 91 - COMMUNICATION
- 91 RADIO, TELEPHONE, NAVIGATION, TRIP COMPUTER for Cabriolet
.

Pull off rubber seal on plenum chamber in direction of - arrow -.
Remove cover - 1 - from plenum chamber.
With the ignition switched off, disconnect battery ground (GND) strap →
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for Cabriolet
.

Fig 4: Removing Securing Clips And Cowl

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Pry off the two caps - 3 -.
Remove nuts - 4 - and remove the two wiper arms - 2 -.
Remove clips - 1 - and disconnect cowl panel grille - 5 -.

Fig 5: Removing Screws And Cover From E-Box In Plenum Chamber

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Remove the electronics box from the plenum chamber as follows:

Unscrew bolts - arrows - and take off the cover.

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

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Use screwdriver to carefully pry off retaining strap - arrow -.
Lay aside engine control module with connectors attached.

Fig 7: Connector At Connector Rail And Wire

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Disconnect connectors - 2 - at connector console.
Remove electrical wiring connection - 1 -.

Fig 8: Locating Auxiliary Relay Carrier Catches

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Release catches - arrows - and lift auxiliary relay carrier out of electronics box.
Pull engine wiring harness together with rubber grommet out through opening in electronics box.

Fig 9: Electronics Box Nuts

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

NOTE:

In the following steps make sure that no brake fluid escapes into the plenum chamber or onto the transmission below. If this does happen, clean the affected area thoroughly.
When performing work in the footwell, put cloths on the carpet to protect it from possible brake fluid spills.

Fig 10: Identifying Brake Fluid Reservoir Return Hose Grommet

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Pinch off supply hose - A - from brake fluid reservoir using hose clamp 3094. Disconnect hose from clutch master cylinder and plug hose.
Remove rubber grommet from bulkhead above connection line for supply hose.
Lever out retaining clip - C - using a screwdriver and then pull out line/hose assembly - B - slightly.

Fig 11: Location Of Brake Fluid Reservoir Dowel Bolt

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Remove bolt for brake fluid reservoir - 1 - and disconnect connector for Brake fluid level warning contact downwards.

NOTE:

The brake fluid reservoir does not have to be removed.

Fig 12: Location Of Brake Servo Securing Bolts

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Remove vacuum line to brake servo - 1 -.
Remove the two TORX bolts - arrows -.

NOTE:

To simplify the illustration, the brake fluid reservoir has not been included.
Brake fluid reservoir must be moved slightly to the side in order to unscrew upper Torx bolt.

Remove storage compartment on drivers side →
- 68 - INTERIOR EQUIPMENT
- 68 - INTERIOR EQUIPMENT for Cabriolet
.
Removing over-center spring → Over-center spring, removing and installing .

Fig 13: Brake Pedal At Brake Servo

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Disconnect brake pedal from brake servo → 47 - BRAKES - HYDRAULIC COMPONENTS .

Fig 14: 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 box - arrowA - → 48 - STEERING .
Disconnect connectors at clutch pedal switch - 1 - , brake pedal switch - 2 - and at accelerator pedal module - 3 -.
If installed, disconnect connector from Clutch Pedal Starter Interlock Switch F194.
Remove securing bolt for mounting bracket - arrowB - and remove entire pedal cluster.

Fig 15: Pressing Retainer Together And Detaching Clutch Pedal From Master Cylinder Using VAG 1922

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Release master cylinder operating rod from clutch pedal as follows:

NOTE:

When releasing the operating rod, make sure that clutch pedal does not collide with mounting bracket for clutch pedal switch - arrow -. The mounting bracket could otherwise break off.

Insert pliers V.A.G 1922 in recesses on clutch pedal, press on sides of retaining clip and Disconnect clutch pedal from master cylinder.

Fig 16: Identifying Retaining Clip, Clutch Pedal, Bolts And Master Cylinder

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Disconnect retaining clip - 1 - and remove clutch pedal - 2 -.
Remove bolts - 3 - and remove clutch master cylinder - 4 -.

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

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Installing

Installation is performed in reverse sequence; note the following:

Install clutch master cylinder - 4 - and tighten bolts - 3 - to 20Nm.

Fig 18: Pushing Clutch Pedal To Lock Into Place, While Making Sure Mount Is Properly Secured In Clutch Pedal

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Install retaining clip - 1 - in clutch pedal.
Lock clutch pedal in position by pressing in direction of - arrow -. Make sure retaining clip - 1 - engages correctly in clutch pedal.

Fig 19: Location Of Clutch Pedal Switch F36 And Pedal Assembly Securing Bolt

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A second technician is required for the next step.

Insert entire pedal cluster and tighten bolt - 1 - by hand. The second technician should guide hose/line assembly into clutch master cylinder from plenum chamber.

Fig 20: Location Of Brake Servo Securing Bolts

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

Fig 21: Installing Rubber Grommet And After-Run Hose

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Press in retaining clip - C - as far as it will go.
Insert hose/line assembly - B - in clutch master cylinder and make sure that it engages audibly.
Install rubber grommet - D - onto connecting line for supply hose - A - at bulkhead.
Push supply hose - A - from brake fluid reservoir on as far as it will go.

Remove hose clamps 3094.

Fig 22: Location Of Brake Fluid Reservoir Dowel Bolt

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Screw in securing bolt - 1 - for brake fluid reservoir and Connect connector at brake fluid level warning contact.

Fig 23: Locating Steering Column At Steering Gear And Disconnecting Connector On Clutch Pedal Switch, Brake Pedal Switch And On Accelerator Pedal Module

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten hexagon socket head bolt - arrowB - for securing pedal cluster to instrument panel carrier to 25Nm.
Connect connectors - 1 - , - 2 - and - 3 -.
If installed, attach connector for Clutch Pedal Starter Interlock Switch F194.
Connect brake pedal to brake servo → 47 - BRAKES - HYDRAULIC COMPONENTS .

Secure steering column to steering box - arrowA - → 48 - STEERING .
Install over-center spring Installing .
Install storage compartment on drivers side →
- 68 - INTERIOR EQUIPMENT
- 68 - INTERIOR EQUIPMENT for Cabriolet
.
Bleed clutch system → Hydraulic clutch system, bleeding .

Fig 24: Electronics Box Nuts

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Install electronics box and tighten nuts -arrows- to 4Nm.
Route engine wiring harness and Connect connector in connector console.
Install engine control module → 24 MULTIPORT FUEL INJECTION (MFI) .
If applicable, install auxiliary relay carrier and auxiliary fuse carrier →
- 97 WIRING
- 97 WIRING for Cabriolet
.

Press on cover (hand-tight) and tighten bolts in diagonal sequence to 4Nm.
Follow steps required after connecting battery →
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for Cabriolet
.

NOTE:

Upon re-connecting the battery, remember to check and activate the vehicle equipment (radio, clock, convenience electrics etc.).