Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 490
1.9
Bearing Bushing, Removing and Instal‐
ling
Removing
Disconnect the battery ground cable. Refer to ⇒ Electrical Equip‐
ment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and Con‐
necting .
– Press together the retainers in the direction of -arrows- and
remove the studs -1- to the right side.
– Turn the valve fitter such that the openings -1- or pin -2- are
visible.
The openings -1- and the pin -2- face in the same direction.
– Remove the bearing bushing -A- from the openings -1-.
Installing
– Turn the valve fitter such that the openings -1- or pin -2- are
visible.
The openings -1- and the pin -2- face in the same direction.
– Fit the bearing bushing -A- in the openings -1- and rotate into
place.
– Use a new mounting pin to connect the valve fitter/clutch mas‐
ter cylinder to the clutch pedal.
– Connect the battery. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27 ; Battery; Battery, Disconnecting and Connecting .
1.10
Clutch Master Cylinder, Removing and
Installing
Removing
Note
♦
Before replacing the clutch master cylinder due to an assumed
defect, perform the
Guided Fault Finding
Vehicle Diagno‐
sis Tester first.
♦
When working inside the footwell, cover the carpet with cloths
to protect it from leaking brake fluid.
– Remove the bracket. Refer to
⇒ “1.8 Mounting Bracket, Removing and Installing”, page 28
.
– Remove the Clutch Position Sensor - G476- . Refer to
⇒ “1.15 Clutch Position Sensor G476 , Removing and Instal‐
.
– Release retainers in the direction of -arrows- and remove
mounting pin -2-.
– Remove clutch master cylinder -1-.
Installing
Install in reverse order of removal. Note the following:
Replace mounting pin after removing.
– Install the bracket. Refer to
⇒ “1.8 Mounting Bracket, Removing and Installing”, page 28
.
– Install the Clutch Position Sensor - G476- . Refer to
⇒ “1.15 Clutch Position Sensor G476 , Removing and Instal‐
.
1.11
Clutch Slave Cylinder with Release
Bearing, Removing and Installing
Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm - VAG1331-
Note
♦
The clutch slave cylinder and the release bearing are a single
unit and are replaced together.
♦
Pay attention to the thread pitch on the bolts when cleaning
the threaded hole in the clutch housing.
Removing
• Transmission is removed.
– Open the clip -2- with a screwdriver or a pointed tool and re‐
move bleeder -4- from clutch slave cylinder -1-.
– Remove the bolts -arrows-.
– Remove the clutch slave cylinder together with the release
bearing -A-.
Installing
Install in the reverse order of removal while noting the following:
• Tighten the slave cylinder bolts in small increments only.
Otherwise, there is the danger that the tabs with the fastening
holes could break off.
– Check the O-ring -3- on the clutch slave cylinder for damage.
– Push the bleeder -4- onto the clutch slave cylinder connection
-1- until the clip -2- clicks into place.
– To check, pull on the bleeder.
– Install the transmission. Refer to
⇒ “2.2 Transmission, Installing”, page 92
.
– Bleed the clutch mechanism. Refer to
⇒ “1.16 Clutch Mechanism, Bleeding”, page 37
Tightening Specifications
♦ Clutch slave cylinder with release bearing to transmission.
Refer to
⇒ “1.4 Overview - Clutch Release Mechanism”, page 21
1.12
Clutch Mechanism Lines, Removing
and Installing
Special tools and workshop equipment required
♦ Hose Clamps - Up To 25mm - 3094-
Removing
– Disconnect the battery ground cable. Refer to ⇒ Electrical
Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and
Connecting .
– Remove the air filter housing if the lines are not accessible.
Vehicles with a Turbo Diesel Engine
– Refer to ⇒ Engine Mechanical, Fuel Injection and Glow Plug;
Rep. Gr. 23 ; Air Filter; Air Filter Housing, Removing and In‐
stalling .
Vehicles with a Gasoline Engine
– Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition;
Rep. Gr. 24 ; Air Filter; Air Filter Housing, Removing and In‐
stalling .
Continuation for All
– Remove the battery and the battery tray. Refer to ⇒ Electrical
Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and
Connecting .
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 fol‐
lowing work. If it does, clean the area thoroughly.
♦ Place a lint-free cloth under the clutch master cylinder.
– Unclamp the supply hose -2- to the clutch master cylinder with
a -3094- .
Note
♦
A slight deformation of the supply hose remains after the
-3094- have been unclamped.
♦
The supply hose is therefore not defective.
♦
After removing the -3094- , the supply hose must be formed
back into its original shape.
– Remove clip for hose/line assembly -1- all the way and remove
hose/line assembly.
– Seal off openings.
– Remove the clip -arrow- all the way and then remove the hose/
line assembly -A- from the bleeder.
Ignore item -B-.
– Seal the open lines and connections with clean plugs if nec‐
essary from the -VAS6122- .
– Free up the hose/line assembly and remove it.
Installing
Install in reverse order of removal. Note the following:
– Connect hose/line assembly -1- with clutch master cylinder.
– Pull on the line to make sure it is secure.
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