Hydraulics System Overview

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Fig 1: Identifying Hydraulic System, Assembly Overview

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Brake Fluid Reservoir
Spring Clamp
- Not on all vehicles.
Supply Hose
- Rubber
- As of 12.05, made of plastic. Refer to Fig 3.
Master Cylinder
- Removing and installing, refer to MASTER CYLINDER .
Circlip
- To remove and install the hose/line assembly or the plastic line, pull the circlip all the way out.
- On some master cylinders, it is pulled out on the side.
Seal/O-ring
- Installed on the line connection.
- Install using brake fluid.
- Seal/O-ring suitable for the line connection. Refer to Fig 2.
Mount
- To remove and install, disconnect the master cylinder from the clutch pedal. Refer to CLUTCH PEDAL .
Clutch Pedal
- Removing and installing, refer to CLUTCH PEDAL .
Self-Locking Nut
- 25 Nm
- Quantity: 3
- For the bracket to the bulkhead.
- Always replace.
Hose/Line Assembly
- To remove, the battery and battery tray need to be removed. Refer to Removal and Installation .
- Removing and installing, refer to CLUTCH HOSE/LINE ASSEMBLY OR PLASTIC LINE .
Bracket
- For the hose/line assembly HOSE/LINE ASSEMBLY.
- Attached to the body.
- Covered by the assembly mounting.
- Bracket differentiation, refer to Fig 4.
Plastic Line
- To remove, the battery and battery tray need to be removed. Refer to Removal and Installation .
- Removing and installing, refer to CLUTCH HOSE/LINE ASSEMBLY OR PLASTIC LINE .
Bracket
- For the plastic line PLASTIC LINE.
- Attached to the body.
- Covered by the assembly mounting.
- Bracket differentiation, refer to Fig 4.
Seal/O-ring
- Installed on the line connection.
- Install using brake fluid.
- Seals/O-ring for the line connection, refer to Fig 2.
Breather
- Removing and installing, refer to BREATHER ASSEMBLY .
Circlip
- To remove and install the hose/line assembly or plastic line and the breather, pull the circlip all the way out.
Vent Valve
- Clutch system, bleeding. Refer to CLUTCH SYSTEM, BLEEDING .
Cap
Clutch Slave Cylinder
- The gasket can only be replaced when the transmission is removed.
- Removing and installing, refer to SLAVE CYLINDER WITH RELEASE BEARING .
Transmission

Fig 2: Identifying Different Line Connections -1 To 3-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Item	Line Connection Version
1	Line connection with a groove all the way around -arrow 1-
2	Line connection with a shoulder -arrow 2-
3	Line connection with a shoulder -arrow 2- and with a groove all the way around -arrow 3-

Fig 3: Identifying Supply Hose & Seals

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The seals -2- must be inside the supply hose -1-.

Fig 4: Identifying Bracket Differentiation

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Dimension "a" mm	Line Version
8	Plastic line
6	Hose/line assembly