Hydraulic System Overview

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Fig 1: Exploded View Of Clutch Hydraulics

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Brake Fluid Reservoir
Gasket
- For the plastic supply hose.
- The seals must be inside the supply hose.
Supply Hose
- To the brake fluid reservoir.
- Plastic, with additional seals. Refer to Fig 3.
Clutch Master Cylinder
- Removing and installing, refer to CLUTCH MASTER CYLINDER .
Clip
- To remove and install the hose/line assembly or line, pull the clip all the way out.
- On some clutch master cylinders, it is pulled out on the side.
Seal/O-Ring
- Installed on the line connection.
- Install using brake fluid.
- Seal or O-ring suitable for the hose/line connection, refer to Fig 2.
- Grease allocation.
Mounting
- To remove and install, disconnect the clutch master cylinder from the clutch pedal. Refer to CLUTCH PEDAL .
Clutch Pedal
- Removing and installing, refer to CLUTCH PEDAL .
Nut
- Tightening specification. Refer to CLUTCH PEDAL OVERVIEW .
- Always replace after removing.
- Self-locking
- Quantity: 3
- For the mounting bracket to the bulkhead.
Hose/Line Assembly
- Use the correct allocation.
- To remove, first remove the battery and battery tray. Refer to Removal and Installation .
- Removing and installing, refer to CLUTCH HYDRAULIC HOSE/LINE OR PIPE .
Bracket
- For the hose/line assembly -item 10-.
- Attached to the body.
- Covered by the assembly mounting.
- Bracket differentiation, refer to Fig 4.
Line
- Grease allocation.
- To remove, first remove the battery and battery tray. Refer to Removal and Installation .
- Removing and installing, refer to CLUTCH HYDRAULIC HOSE/LINE OR PIPE .
Bracket
- For the line -item 12-.
- Attached to the body.
- Covered by the assembly mounting.
- Bracket differentiation, refer to Fig 4.
Seal or O-ring
- Installed on the line connection.
- Install using brake fluid.
- Seal or O-ring suitable for the line connection, refer to Fig 2.
- Grease allocation.
Bleeder Assembly
- Removing and installing, refer to BLEEDER ASSEMBLY .
Clip
- To remove and install the hose/line assembly or line and bleeder, pull the clip all the way out.
Bleed Valve
- 4.5 Nm
- Bleed the clutch system, refer to CLUTCH SYSTEM, BLEEDING .
Dust Cap
Clutch Slave Cylinder
- The gasket can only be replaced when the transmission is removed.
- Removing and installing, refer to CLUTCH SLAVE CYLINDER WITH RELEASE BEARING .
Transmission

Fig 2: Identifying Different Line Connections

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-

The seal/O-ring must be installed in the groove -arrows 1- and -arrow 3-.

Fig 3: Identifying Supply Hose & Seals

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 4: Identifying Bracket Differentiation

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Dimension -a-	Line Version
8 mm	Line
6 mm	Hose/Line Assembly