ECU AUDI A6 1996 C5 / 2.G 01E Transmission Clutch Mechanism Service Workshop Manual

30-4


Parts catalog 12 -
Over-center spring
AllocationRemove and install with clutch pedal
Page 30
-5
13 -
Hex socket head bolt, 5 Nm
Secures clutch and brake pedal pivot pin
14 -
Seal Must not be removed
15 -
Torx bolt - 25 Nm Also secures the brake master cylinder
with brake servo
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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


Note:

For the following procedures, make sure that the clutch pedal does not
press out switch (arrow) from securing clip, since the thread of the
switch would be damaged and the switch would have to be replaced. To ensure proper securing, the switch (arrow) may only be installed
once.

- Detach clutch pedal from master cylinder. To do this, unclip pin using a
screwdriver (arrow -1-) and pull out pin (arrow -2-).
- Press clutch pedal securing clip off pivot pin with a screwdriver.
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30-6


- Unscrew bolt (arrow).
- Press clutch and brake pedal pivot pin out to the right, until the clutch
pedal can be removed.
- If necessary press brake pedal securing clip off pivot pin with a
screwdriver.
- Take out clutch pedal and over-center spring.
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30-7

Installing
Installation is carried out in the reverse order,
when doing this note the following:

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

Do not tighten bolt (arrow) until both securing clips have been fitted on the
clutch pedal/brake pedal pivot pin.
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30-8


Note:
To ensure proper securing, the switch may only be installed once. - Check adjustment of switch -1- via clutch pedal as follows:

Switch -1- must sit completely against clutch pedal -3- and must be
completely activated.
Adjustment specification: The gap measurement -a- between
securing clip and mounting bracket -2- or gap measurement -b- at
switch -1- be no larger than 0.5 mm.
To adjust, clamp must be held and switch -1- must be turned.
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30-10


6 -
Clip
7 -
Harness connector bracket
8 -
Clutch Pedal Position (CPP) Switch -F
194-
Adjusting Page 30
-11
9 -
Clip
10 -
Screw and washer assembly
8 Nm
11 -
Securing plate
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30-11

Clutch Pedal Position (CPP) switch -
F194-, adjusting


- Loosen two bolts (arrow) slightly.
- Have second technician depress clutch pedal to stop.
-
Insert feeler gauge -A-, with selected measurement -a- 3.2 0.2 mm,
between activation surface of clutch pedal and switch plunger. - Tilt switch -B- toward feeler gauge -A- to stop and tighten both securing
bolts (arrows) to 8 Nm.
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30-14


12 -
Plastic slave cylinder
Do not operate clutch pedal after slave
cylinder has been removed Brake fluid must not be allowed to get onto
the transmission Lightly grease to install Fig. 1When installing push in until the securing
bolt can be fitted. With plug-in connection for hose/line
assembly Disconnecting hose/line assembly Fig. 2Follow correct sequence of work when
bleeding Page 30
-25
.
13 -
Bleeder valve
Tighten to 4.5 NmFollow correct sequence of work when
bleeding Page 30
-25

A broken off bleeder valve can be removed
using a 3mm hex socket wrench
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30-15


14 -
Dust cap
15 -
Retaining clip
Pull out retaining clip to disconnect line
Fig. 2

16 -
Bracket
Secured to transmission
17 -
Hex socket head bolt 20 Nm
18 -
Nut 2 Nm
19 -
Seal
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30-18


Note: - Unscrew both nuts -A-.
- Lift E-box off studs at the rear and then pull it out of securing point -B-.
In the following procedures, 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. When performing work in the footwell, put cloths on the carpet to
protect it from possible brake fluid spills.

- Clamp supply hose -A- from brake fluid reservoir using special tool
3094. Pull hose off master cylinder and plug hose.
- Remove rubber grommet for compensation hose above connecting line
from transverse wall.
- Pry out retaining clip -C- using a screwdriver and pull line -B- out
slightly.
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