brake fluid AUDI A4 1996 B5 / 1.G 01A Transmission Clutch Mechanism Service Workshop Manual

Repair Manual,
Body Interior, Repair Group 68


Make sure that no brake fluid escapes into the
plenum chamber or onto the transmission
below. If this does happen, clean the affected
areas thoroughly.
Pa
ge 2 of 22 Clutch mechanism, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.30.1

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
Pa
ge 11 of 22 Clutch mechanism, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.30.1

30-11


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
-17

Pa
ge 12 of 22 Clutch mechanism, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.30.1

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.
Pa
ge 16 of 22 Clutch mechanism, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.30.1

30-16

- 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).
Pa
ge 18 of 22 Clutch mechanism, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.30.1

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.
Pa
ge 19 of 22 Clutch mechanism, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.30.1

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.
Pa
ge 20 of 22 Clutch mechanism, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.30.1

Top-off brake fluid reservoir to "max." marking
with brake fluid before bleeding clutch system.

- Pull clutch pedal back to rest position.

- Connect VAG1238B brake filling and bleeding
appliance or VAG1869 but do not switch on.

- If necessary, remove noise insulation panel
under transmission.
Pa
ge 21 of 22 Clutch mechanism, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.30.1

30-19


CAUTION!
Always comply with disposal regulations.
Note:
While bleeding, make sure bleeder hose remains correctly routed. - Connect bleeder hose -A- to clutch slave cylinder (arrow) and open
bleeder valve.
- Connect bleeder hose with pressure hose to collector bottle.
- Switch on bleeding appliance and let approx. 100 cm3 (approx. 3.4 fl.
oz) brake fluid flow into suitable collection reservoir.
Work pressure 2.5 bar (36 psi)
- Close bleeder valve.
Tightening torque: 4.5 Nm (40 in. lb).
- Depress clutch pedal several times after completion of bleeding
process.
- Bleed system again if necessary.
Pa
ge 22 of 22 Clutch mechanism, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.30.1