AUDI A4 1996 B5 / 1.G 01A Transmission Clutch Mechanism Service User Guide

30-10


Clutch hydraulic system, servicing

1 -
Brake fluid reservoir
2 -
Supply hose
For clutch master cylinder
3 -
Hose/line assembly With threaded connections on clutch
master cylinder and clutch slave cylinder
4 -
Line fitting 15 Nm (11 ft lb)
5 -
Mounting bracket
6 -
Clutch pedal Removing and installing Page 30
-5
7 -
Socket-head bolt
20 Nm (15 ft lb)
8 -
9Pin and locking plate
10 -
Clutch master cylinder Removing and installing Page 30
-13
11 -
Transmission
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CAUTION!
Do not operate after the clutch pedal has been
removed.
Brake fluid must not be allowed to get onto the
transmission.
CAUTION!
Fill the brake fluid reservoir up to the "max"
marking with brake fluid before bleeding the
hydraulic clutch system with the brake bleeder. 12 -
Clutch slave cylinder

Coat plunger of clutch slave cylinder with
copper grease e.g. Z381 351 TE
For clutch slave cylinders with plastic support
ring, lightly lubricate outer surface of ring before
installing
When installing, push in until bolt can be
installed
13 -
Bleeder valve
4.5 Nm (40 in. lb)Observe all CAUTIONS, WARNINGS,
Notes and procedures when bleeding
Page 30
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14 -
Bracket
Mounted to transmission
15 -
Bolt

8DVA 000 504 bolt:25 Nm (18 ft lb)

8DVA 000 505 socket-head bolt:20 Nm (15 ft lb)
16 -
Nut 2 Nm (18 in. lb)
17 -
Seal
18 -
Seal Must not be removed
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30-13

Clutch master cylinder, removing and
installing


Special tools and equipment
3094 hose clamp

Removing

CAUTION!

Before working on the electrical system:

Determine the correct coding for the anti-
theft radio.
Switch the ignition off (also applies when
connecting the battery). Failure to do so may
damage the Engine Control Module (ECM).
Disconnect the battery Ground (GND)
strap.
To remove E-box from plenum chamber:

- Remove bolts (arrows) and remove cover.
- Remove Engine Control Module (ECM); if necessary remove 8-pin
relay support Repair Manual, Electrical Equipment, Repair Group 97- Disconnect harness connectors at connector station.
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- Remove engine wiring harness together with rubber grommet from
opening in E-box.
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30-14


CAUTION! - Remove both nuts -A-
- Lift E-box out at rear of threaded bolt and remove from mounting point -
B-.
When carrying out the following steps, make sure that no brake
fluid escapes into the plenum chamber or onto the transmission
below. If this does occur, clean thoroughly. When working in the area of the footwell, make sure to protect the
carpeting from brake fluid which may run out.

- Clamp supply hose -A- from brake fluid reservoir using 3094 hose
clamp. Pull hose off clutch master cylinder and plug hose.
- Disconnect line -B- from clutch master cylinder and seal.
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30-15

- Remove
driver's side
storage
compartment
Repair Manual,
Body Interior, Repair Group 68


- Remove switch above clutch pedal if installed
Page 30
-7

Installing
Installation is the reverse of removal, note the following: - Unclip pin using screwdriver (arrow -1-), pull out pin (arrow -2-), and
detach clutch pedal from clutch master cylinder.
- Unbolt clutch master cylinder from passenger compartment.

- When replacing clutch master cylinder, check dimension -a- on ball
head and adjust if necessary.

Dimension -a- = 165 0.5 mm (6.496 0.020 in.)
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- Connect clutch master cylinder to clutch pedal.
Secure pin and locking plate on clutch pedal.

To install E-box in plenum chamber: - Tighten line fitting -B- to clutch master cylinder to 15 Nm (11 ft lb).
- Slide hose -A- onto brake fluid reservoir up to stop.
- Bleed hydraulic clutch system after installing clutch master cylinder
Page 30
-17
.

- Always replace seal -C-.
- Make sure seal is positioned properly, and does not cover opening or
stepped metal edge.
- Install E-box by hand and evenly tighten nuts -A- to 4 Nm (35 in. lb)
(i.e. imprint on E-box cover).
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30-17

Clutch system, bleeding


Special tools and equipment

VAG1238B brake filling and bleeding appliance
or
VAG1869 brake filling and bleeding appliance

WARNING!

Brake fluid is poisonous.
It must NEVER be removed by siphoning
with your mouth.
If brake fluid contacts skin or eyes, flush or
wash adequately to prevent irritation. Get
medical attention immediately if necessary.
Brake fluid must be disposed of properly.
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30-18

CAUTION!

Use only fresh brake fluid conforming to US
standard FMVSS 116 DOT 4. Genuine
VW/Audi brake fluid conforms to this
specification.
Brake fluid must never be brought into
contact with liquids containing mineral oil
(gasoline, cleaning agents). Mineral oil
damages the pistons and cups in the braking
system.
Brake fluid must not be allowed to come into
contact with paintwork because of its caustic
effect.
Brake fluid is hygroscopic (i.e. it absorbs
moisture from the surrounding air) and
should therefore always be kept in airtight
containers.
When carrying out the following steps, make
sure that no brake fluid escapes onto the
transmission.

Notes:
The clutch system must be bled after carrying
out work on the hydraulic clutch mechanism.
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