Clutch Position Sensor -G476-: Removing

WARNING: This page is about a different car, the 2013 Volkswagen Beetle and 2012 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

-- Turn off the ignition and disconnect the battery ground cable, refer to [For engine(s) CVCA, CPRA, CBTA, CPKA, CPLA, CJAA, CBUA, CPPA, CCTA, CBFA] Removal and Installation .

-- Remove the air filter housing, refer to REMOVAL AND INSTALLATION .

-- Remove the battery and the battery tray, refer to [For engine(s) CVCA, CPRA, CBTA, CPKA, CPLA, CJAA, CBUA, CPPA, CCTA, CBFA] Removal and Installation .

-- Clamp off the supply hose -A- to the clutch master cylinder using a Hose Clamps up to 25 mm Diameter 3094.

Fig 1: Identifying Supply Hose, Noise Insulation And Lock Washer

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

It is necessary to remove the noise insulation -B- as follows from the bulkhead in order to access the Clutch Position Sensor -G476- :

-- Remove the retainer -C-.

-- Fold the noise insulation -B- near the clutch master cylinder forward in the -direction of the arrow-.

NOTE: It is not necessary to remove the noise insulation -B- completely.

If a hose/line assembly -3- with a round component is installed directly below the clutch master cylinder, then the hose/line assembly must be removed.

Fig 2: Identifying Circlip Pulled Out Using Screwdriver Or Pointed Tool To Remove Line From Master Cylinder

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

CAUTION: Danger of leaking brake fluid.

Be careful not to get any brake fluid on the longitudinal member or on the transmission when performing the following work. If it does, clean the area thoroughly.
Place a lint-free cloth under the clutch master cylinder.

-- Unclamp the supply hose from the clutch master cylinder with Hose Clamps up to 25 mm Diameter 3094.

Fig 3: Identifying Hose Clamps 3094, Clamp Supply Hose And Master Cylinder

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

A slight deformation of the supply hose remains after the Hose Clamps up to 25 mm Diameter 3094 have been unclamped.

The supply hose is therefore not defective.

After removing the Hose Clamps up to 25 mm Diameter 3094, the supply hose must be formed back into its original shape.

-- Disengage the clip -2- using a screwdriver or a pointed tool and pull the clutch master cylinder out until it stops.

Fig 4: Identifying Circlip Pulled Out Using Screwdriver Or Pointed Tool To Remove Line From Master Cylinder

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the hose/line assembly or pipe -3- from the clutch master cylinder and seal it.

-- Disconnect the connector -4-.

-- Remove the Clutch Position Sensor -G476- from the clutch master cylinder -arrow-.