AUDI A4 1996 B5 / 1.G 01W Transmission Clutch Mechanism Servicing User Guide

30-11

Clutch master cylinder, removing and
installing


Special tools and equipment
3094 hose clamp

Removing
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.
- Remove engine wiring harness together with rubber grommet from
opening in E-box.
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30-12


Notes: - 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 floor area cover the carpet with a cloth to protect
against any leaking brake fluid.

- 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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30-13

- Remove driver's side storage compartment
Repair Manual, Body Interior, Repair Group 68.
- Remove clutch pedal position switch if installed
Page 30
-6 .

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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30-14

- 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
-15
.

- Always replace seal -C-.
- Make sure seal is positioned properly, and does not cover opening or
stepped metal edge.
- Install E-box into mounting point -B-.
- Tighten nuts -A- to 4 Nm (35 in. lb).
- Install cap and hand tighten in diagonal sequence to 4 Nm (35 in. lb)
imprint on E-box cover.
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30-15

Clutch system, bleeding


Special tools and equipment

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

Notes:
When carrying out the following steps, make
sure that no brake fluid escapes onto the
transmission.
The clutch system must be bled after carrying
out work on the hydraulic clutch mechanism.
Top off brake fluid reservoir to "MAX." mark
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.
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30-16


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.
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