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

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.
Pa
ge 11 of 27 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.TM03.30.1

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
Pa
ge 14 of 27 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.TM03.30.1

30-16


Fig. 1 Installing clutch slave cylinder
- Coat area -a- of collar with lithium grease G 052 150 A2 before
installing slave cylinder into transmission housing.
- Lightly coat contact surface for plunger to clutch release lever with
copper grease, e.g. Z 381 351 TE.

Removing
Installing Fig. 2 Disconnecting line and clutch slave cylinder
- To disconnect line, use a screwdriver to pry out retaining clip -A- so
that it clicks. Line can then be pulled out.
- Press in retaining clip -A- as far as it will go.
- Push line into slave cylinder until it engages audibly.
Pa
ge 16 of 27 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.TM03.30.1

30-17

Master cylinder, removing and installing


Special tools, testers and auxiliary items

Removing
Remove E-Box from plenum chamber as follows:
Hose clamp 3094
- If installed, remove cover above plenum chamber.
- Disconnect battery Ground (GND) strap with the ignition switched off.

Repair Manual, Electrical Equipment, Repair Group 97
- Pull off clip -1- and lift wind grill -A- slightly. Now remove screw (arrow -
2-).
- Remove remaining screws (arrows) and remove cover.
- Remove engine control unit and 8-point relay carrier (if fitted)
- Unplug connector in connector station.
- Pull engine wiring harness together with rubber grommet out through
opening in electronics box.
Pa
ge 17 of 27 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.TM03.30.1

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.
Pa
ge 18 of 27 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.TM03.30.1