Installing Clutch Pedal

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Information

Grease bracket in area of pedal bearing axle -arrows- with Renocal (Glissando VW 745). Part No. 000.043.206.21 (10g tube).

Fig 1: Locating Lubrication Areas Of Pedal Bearing Axle Bracket

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

IMPORTANT: By contrast with previous models, do not grease the pedal bearing axle in the area of the clutch pedal -A- (due to plastic-coated bearing sleeves).

Also grease the following contact surfaces with Renocal (Glissando VW 745) (Part No. 000.043.206.21): The clutch pedal switch (interlock switch) system -arrow- . In addition, the contact surface between the clutch pedal (inside of prongs) -arrow- and the guiding rods of the clutch power spring -arrow- .

Check bearings on the clutch power spring/clutch pedal (bushes, bearing shells) and the connection pieces for signs of wear. Replace any parts that are worn. Use new lock for pin.

Observe correct tightening torques.

When installing the bracket for clutch power spring, insert the valve pushrod for the master cylinder carefully into the specified position in the clutch pedal.

If creaking noises (over approx. 2/3 of the lift area) are heard after installing the clutch pedal, these may be coming from the connection between the ball head piston rod and piston seat of the clutch master cylinder -arrow- . In this case, spray a minimal amount of multipurpose oil on the connection point using a metering tube -arrow- . Important: The lubricant must only be applied to this connection point so make sure not to use too much. This connection point cannot be taken apart without damaging it irreparably.

Fig 2: Locating Clutch Master Cylinder (Push Rod)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Insert bracket for clutch power spring with clutch pedal.
Install support for clutch pedal switch.
Position support for clutch pedal switch (and interlock switch, if necessary) in the correct position. Observe the auxiliary bar! -Arrow- The auxiliary bar must be fitted in the correct position in the groove.

Fig 3: Identifying Auxiliary Bar
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install clutch power spring.
Observe the installation position of the bolt for the clutch power spring (hexagon). After installation, remove the clutch power spring cotter pin.
Fit the clutch master cylinder.
Information

Insert pin. Screw in the fastening screws slightly so that the master cylinder can still be moved. Have the clutch pedal not actuated at the limit stop. Press the clutch master cylinder in the direction of travel and tighten (make sure the return bore in the clutch master cylinder is not blocked!).
Check adjustment for clutch pedal switch (and interlock switch, if necessary).
Information

If the clutch pedal switch adjustment (interlock switch) has been changed, the adjustment must be checked or adjusted. The switch must switch when the clutch pedal is actuated approx. 1-2 mm before the limit stop of the clutch master cylinder.

→ Adjustment for clutch pedal switch (interlock switch) Plug in connector.

Fig 4: Checking Clutch Pedal Switch Adjustment (Interlock Switch)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install device support.
The device support is installed at the left next to the clutch pedal together with the vehicle electrical system control unit and relay carrier.
1. 6.1. Install device support.
2. 6.2. Install vehicle electrical system control unit.
3. 6.3. Install relay carrier.
Install side trim panel, fuse box and lid.
In driver's footwell at the left.