lock AUDI A4 1999 B5 / 1.G 01A Transmission Clutch Mechanism Service Workshop Manual

30-3


CAUTION!
Do not operate after the clutch pedal has been
removed. 2 -
Pivot pin
For clutch and brake pedalsInstallation position: groove (arrow) facing
clutch pedal
3 -
Locking clip
4 -
Socket-head bolt 25 Nm (18 ft lb)
5 -
Brake pedal
6 -
Clutch pedal Removing and installing Page 30
-5
7 -
8Pin and locking plate
Clip onto clutch pedal
9 -
Locking clip
10 -
Clutch master cylinder Removing and installing Page 30
-13
11 -
Socket-head bolt
20 Nm (15 ft lb)
Pa
ge 4 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

30-5

Clutch pedal and over-center spring,
removing and installing


Removing

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

- If installed, remove switch above clutch pedal.
- Unclip pin and locking plate using screwdriver (arrow -1-), remove pin
and locking plate (arrow -2-), and detach clutch pedal from clutch
master cylinder.
- Press locking clip for clutch pedal off pivot pin using screwdriver.

- Remove bolt (arrow).
- Press clutch and brake pedal pivot pin out toward right, until clutch
pedal can be removed.
- If necessary, press locking clip for brake pedal off pivot pin using
screwdriver.
- Remove clutch pedal and over-center spring.
Pa
ge 6 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

30-6

Installing
Installation is the reverse of removal, note the
following:

- Align pivot pin so that it protrudes out of mounting bracket on clutch
pedal side (arrow).
- Hook clutch pedal into over-center spring, then install onto pivot pin.
- Connect clutch pedal to master cylinder. Clip locking pin onto clutch
pedal.

- Do not tighten bolt (arrow) until both securing clips have been installed
on pivot pin.
Pa
ge 7 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

30-7


Clutch Pedal Position (CPP) switch -F194-,
removing and installing

Note:
The clutch pedal position switch -F194- allows the
engine to be started only with the clutch pedal
depressed. Introduction 05.97
1 -
Mounting bracket
Before removing, remove steering column
from steering gear Repair Manual, Suspension, Wheels, Steering, Repair Group 48

2 -
Cable bracket
3 -
Locking clip
4 -
Pin and locking plate
Latched in clutch pedal
5 -
Clutch pedal Removing and installing Page 30
-5
6 -
Clip
Pa
ge 8 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

30-16

- 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