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    30-1 Clutch Mechanism Service

    Uploaded by

    mefisto06c
    The document provides instructions for servicing the clutch mechanism on an Audi vehicle. It describes removing and installing various clutch components such as the clutch pedal, clutch master cylinder, and clutch slave cylinder. Safety precautions are provided, including warnings to prevent brake fluid from contacting the transmission and to determine the correct antitheft radio coding before disconnecting the battery. Lubrication points and tightening specifications are also included.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    30-1 Clutch Mechanism Service

    Uploaded by

    mefisto06c
    89 views22 pages
    The document provides instructions for servicing the clutch mechanism on an Audi vehicle. It describes removing and installing various clutch components such as the clutch pedal, clutch master cylinder, and clutch slave cylinder. Safety precautions are provided, including warnings to prevent brake fluid from contacting the transmission and to determine the correct antitheft radio coding before disconnecting the battery. Lubrication points and tightening specifications are also included.

    Copyright

    © © All Rights Reserved

    Available Formats

    PDF, TXT or read online from Scribd

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    The document provides instructions for servicing the clutch mechanism on an Audi vehicle. It describes removing and installing various clutch components such as the clutch pedal, clutch master cylinder, and clutch slave cylinder. Safety precautions are provided, including warnings to prevent brake fluid from contacting the transmission and to determine the correct antitheft radio coding before disconnecting the battery. Lubrication points and tightening specifications are also included.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    89 views22 pages

    30-1 Clutch Mechanism Service

    Uploaded by

    mefisto06c
    The document provides instructions for servicing the clutch mechanism on an Audi vehicle. It describes removing and installing various clutch components such as the clutch pedal, clutch master cylinder, and clutch slave cylinder. Safety precautions are provided, including warnings to prevent brake fluid from contacting the transmission and to determine the correct antitheft radio coding before disconnecting the battery. Lubrication points and tightening specifications are also included.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 22

    Clutch mechanism, servicing

    Page 1 of 22

    30-1

    Clutch mechanism, servicing


    CAUTION!
    Before disconnecting the battery:
    Determine the correct coding for the antitheft radio.
    Switch the ignition off (also applies when
    connecting the battery). Failure to do so may
    damage the Engine Control Module (ECM).
    Part numbers are listed here for reference
    only. Always check with your Parts
    department for the latest information.
    Notes:
    Lubricate all bearings and contact surfaces with
    G 052 142 A 2 polycarbamide grease.
    Before
    working on
    the pedal
    cluster,
    remove the
    driver's side
    storage
    compartment

    http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.TM02.30.1

    11/19/2002

    Clutch mechanism, servicing

    Page 2 of 22

    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.

    http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.TM02.30.1

    11/19/2002

    Clutch mechanism, servicing

    Page 3 of 22

    30-2

    Clutch pedal and clutch control overview


    WARNING!
    Clutch pedal travel must not be restricted by
    extra carpets or floor mats.
    Do not re-use fasteners that are worn or
    deformed in normal use.
    Some fasteners are designed to be used only
    once, and are unreliable and may fail if used
    a second time. This includes, but is not
    limited to, nuts, bolts, washers, circlips and
    cotter pins. Always follow recommendations
    in this manual-replace these fasteners with
    new parts where indicated, and any other
    time it is deemed necessary by inspection.
    1 - Mounting bracket
    Removing and installing Repair Manual,
    Brake System, Repair Group 46

    http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.TM02.30.1

    11/19/2002

    Clutch mechanism, servicing

    Page 4 of 22

    30-3

    2 - Pivot pin
    For clutch and brake pedals
    Installation 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

    CAUTION!
    Do not operate after the clutch pedal has been
    removed.
    11 - Socket-head bolt
    20 Nm (15 ft lb)

    http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.TM02.30.1

    11/19/2002

    Clutch mechanism, servicing

    Page 5 of 22

    30-4

    12 - Mount
    Insert in mounting bracket with over-center
    spring
    13 - Over-center spring
    Application

    Parts catalog microfiche

    Remove and install together with clutch


    pedal Page 30-5
    14 - Socket-head bolt
    5 Nm (44 in. lb)
    Secures pivot pin for clutch and brake
    pedal.
    15 - Seal
    16 - Torx

    bolt

    25 Nm (18 ft lb)
    Also secures brake master cylinder to
    brake servo

    http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.TM02.30.1

    11/19/2002

    Clutch mechanism, servicing

    Page 6 of 22

    30-5

    Clutch pedal and over-center spring,


    removing and installing
    Removing
    - Remove driver's side storage compartment
    Interior, Repair Group 68

    Repair Manual, Body

    - 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.

    http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.TM02.30.1

    11/19/2002

    Clutch mechanism, servicing

    Page 7 of 22

    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.

    http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.TM02.30.1

    11/19/2002

    Clutch mechanism, servicing

    Page 8 of 22

    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

    http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.TM02.30.1

    11/19/2002

    Clutch mechanism, servicing

    Page 9 of 22

    30-8

    7 - Bracket for harness connector


    8 - Clutch Pedal Position (CPP) switch -F194Adjusting

    Page 30-9

    9 - Clip
    10 - Screw and washer assembly
    8 Nm (71 in. lb)
    11 - Mounting plate

    http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.TM02.30.1

    11/19/2002

    Clutch mechanism, servicing

    Page 10 of 22

    30-9

    Clutch Pedal Position (CPP) switch F194-, adjusting


    - Loosen two bolts slightly (arrows).
    - Have second technician fully depress clutch pedal up to stop.
    - Place feeler gauge -A- with specific dimension -a- 3.2 mm (0.126 in.)
    between operating surface of clutch pedal and switch cam.
    Thickness -a- of feeler gauge: 3.2 mm (0.126 in.)
    - Move switch -B- toward gauge -A- until stop, and tighten two mounting
    bolts (arrows) to 8 Nm (71 in. lb).

    http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.TM02.30.1

    11/19/2002

    Clutch mechanism, servicing

    Page 11 of 22

    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

    http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.TM02.30.1

    11/19/2002

    Clutch mechanism, servicing

    Page 12 of 22

    30-11

    12 - Clutch slave cylinder


    CAUTION!
    Do not operate after the clutch pedal has been
    removed.
    Brake fluid must not be allowed to get onto the
    transmission.
    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
    CAUTION!
    Fill the brake fluid reservoir up to the "max"
    marking with brake fluid before bleeding the
    hydraulic clutch system with the brake bleeder.

    http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.TM02.30.1

    11/19/2002

    Clutch mechanism, servicing

    Page 13 of 22

    30-12

    14 - Bracket
    Mounted to transmission
    15 - Bolt
    8DVA 000 504 bolt:
    25 Nm (18 ft lb)
    8DVA 000 505

    socket-head bolt:

    20 Nm (15 ft lb)
    16 - Nut
    2 Nm (18 in. lb)
    17 - Seal
    18 - Seal
    Must not be removed

    http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.TM02.30.1

    11/19/2002

    Clutch mechanism, servicing

    Page 14 of 22

    30-13

    Clutch master cylinder, removing and


    installing
    Special tools and equipment
    3094 hose clamp
    Removing
    CAUTION!
    Before working on the electrical system:
    Determine the correct coding for the antitheft radio.
    Switch the ignition off (also applies when
    connecting the battery). Failure to do so may
    damage the Engine Control Module (ECM).
    Disconnect the battery Ground (GND)
    strap.
    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.

    http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.TM02.30.1

    11/19/2002

    Clutch mechanism, servicing

    Page 15 of 22

    - Remove engine wiring harness together with rubber grommet from


    opening in E-box.

    http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.TM02.30.1

    11/19/2002

    Clutch mechanism, servicing

    Page 16 of 22

    30-14

    - Remove both nuts -A- Lift E-box out at rear of threaded bolt and remove from mounting point B-.
    CAUTION!
    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.

    http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.TM02.30.1

    11/19/2002

    Clutch mechanism, servicing

    Page 17 of 22

    30-15

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

    - Remove switch above clutch pedal if installed


    Page 30-7
    - 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.
    Installing
    Installation is the reverse of removal, note the following:

    - When replacing clutch master cylinder, check dimension -a- on ball


    head and adjust if necessary.
    Dimension -a- = 165

    0.5 mm (6.496

    http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.TM02.30.1

    0.020 in.)

    11/19/2002

    Clutch mechanism, servicing

    Page 18 of 22

    30-16

    - Connect clutch master cylinder to clutch pedal.


    Secure pin and locking plate on clutch pedal.
    - 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 .
    To install E-box in plenum chamber:

    - 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).

    http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.TM02.30.1

    11/19/2002

    Clutch mechanism, servicing

    Page 19 of 22

    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.

    http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.TM02.30.1

    11/19/2002

    Clutch mechanism, servicing

    Page 20 of 22

    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.

    http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.TM02.30.1

    11/19/2002

    Clutch mechanism, servicing

    Page 21 of 22

    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.

    http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.TM02.30.1

    11/19/2002

    Clutch mechanism, servicing

    Page 22 of 22

    30-19

    - 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.
    CAUTION!
    Always comply with disposal regulations.
    Work pressure 2.5 bar (36 psi)
    Note:
    While bleeding, make sure bleeder hose remains correctly routed.
    - 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.

    http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.TM02.30.1

    11/19/2002

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