AUDI A6 1996 C5 / 2.G 01E Transmission Clutch Mechanism Service Owner's Manual

30-21

Installing
Installation is the reverse order of removal, while
noting the following:

A second technician is necessary for the next work step. - Insert master cylinder so that the so that seal -1- with washer sits
behind bearing mount and tighten bolts -2- to 20 Nm.
- Press connecting line -3- with guide -arrow A- into groove -arrow B- at
mounting bracket.

- Slide complete pedal assembly forward, toward transverse wall, insert
bolt (arrow -3-) and tighten by hand. At the same time, second
technician must insert tube from plenum chamber into master cylinder.
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30-22


- Tighten bolts for brake booster (arrows) to 25 Nm.

- Press securing clip -C- in to stop.
- Insert tube -B- into master cylinder until the tube engages audibly.
- Insert rubber grommet -D- into transverse wall above connecting
tube/after-run hose -A-.
- Slide on after-run hose -A- to brake fluid reservoir to stop.
- Remove special tool 3094.
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30-23


- Tighten socket head bolt (arrow) for pedal assembly to 25 Nm.
- Connect master cylinder to clutch pedal. Engage bolt lock into clutch
pedal.
- Bleed clutch system after installing master cylinder Page 30
-25
.

Note:
Connect clutch master cylinder with clutch pedal. Engage bolt lock in
clutch pedal. - Check adjustment of switch -1- above clutch pedal as follows:

Switch -1- must lie against clutch pedal -3- completely and must be
completely activated.
Adjustment tolerance: gap measurement -a- between retaining clip
and mounting bracket -2- or gap measurement -b- at switch -1-
may be a maximum of 0.5 mm.
To adjust, hold clip and rotate switch -1-.
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30-24

- Remove driver's side storage compartment:

Repair Manual, Body Interior, Repair Group
68


Repair Manual, Electrical Equipment, Repair Group 97
- Always replace seal -C-.
- Make sure seal does not cover chassis opening and elevated edge of
sheet metal.
- Insert E-Box in securing point -B- and tighten nuts -A- to 4 Nm.
- Press cover on by hand and tighten bolts -A- diagonally to 4 Nm (also
see inscription on cover).
- Install engine wiring harness and connect harness connector in
connector station.
- Install engine control module and if necessary, auxiliary relay carrier
and auxiliary fuse holder.
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30-25

Clutch system, bleeding


Special tools, testers and auxiliary items

Brake filling and bleeding appliance V.A.G 1238
B
or
Brake filling and bleeding appliance V.A.G
1869

Note:
First open bleeder valve before switching on
bleeding appliance.
When performing the following steps, make
sure that no brake fluid escapes onto the
transmission.
The clutch system must be bled after
performing work on hydraulic clutch
mechanism.
Top-up brake fluid reservoir to "max." marking
with brake fluid before bleeding clutch system.

- Pull clutch pedal back to its normal position.
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- Connect brake filling and bleeding appliance
V.A.G 1238 B or V.A.G 1869, but do not switch
on at this stage.
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30-26


Note:
Ensure bleeder hose is correctly fitted during bleeding operation. - Connect bleed hose -A- to slave cylinder (arrow) and open bleed valve.
- Connect bleeder hose to pressure hose of fluid collector bottle.
- Switch on bleeder appliance and allow about 100 cm3 of brake fluid to
drain out.
Working pressure: 2.5 bar
- Close bleeder valve and tighten to 4.5 Nm.
- Depress clutch pedal several times after completion of bleeding
process.
- Bleed system again if necessary.
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