Get Clutch -> 1.5 Mounting Bracket, Removing and Installing Guide for Volkswagen Golf 4 Door Fifth Generation (2003-2008)

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

1.5

Mounting Bracket, Removing and Instal‐

ling

⇒ “1.5.1 Tightening Specifications”, page 40

Special tools and workshop equipment required

♦ Hose Clamps - Up To 25mm - 3094-

♦ Hose Clip Pliers - VAS6362-

♦ Sealing Tool - T10249-

Removing

– First check whether a coded radio is installed. If so, obtain the

anti-theft code.

– Disconnect the battery ground cable. Refer to ⇒ Electrical

Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and

Connecting .

– Remove entire air filter housing if it is located near the battery.

Refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection System; Air

Filter Housing, Removing and Installing or ⇒ Rep. Gr. 24 ; Air

Filter; Air Filter Housing, Removing and Installing .

– Remove the battery and the battery tray. Refer to ⇒ Electrical

Equipment; Rep. Gr. 27 ; Battery; Battery, Removing and In‐

stalling .

Note

♦ While performing the following work, make sure no brake fluid

comes into contact with the longitudinal member or the trans‐

mission. If it does, clean the area thoroughly.

♦ Place a lint-free cloth under the clutch master cylinder.

– Clamp off the supply hose to the clutch master cylinder using

Hose Clamps - Up To 25mm - 3094- .

1. Clutch Mechanism, Servicing

35

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– Loosen the spring clamp -3- using the Hose Clip Pliers -

VAS6362- and remove the return hose from the clutch master

cylinder.

– For disconnecting, seal it with Sealing Tool - T10249/1- (⇒ top

illustration).

– Open the clip -2- with a screwdriver or pointed tool and remove

the hose/line assembly and the pipe -1- on the clutch master

cylinder.

– Unclip the Clutch Position Sensor - G476- from the clutch

master cylinder -arrow- and remove it with the connector -4-

still connected.

Note

When working in the floor area, cover the carpet with a cloth to

protect against any leaking brake fluid.

– Remove the trim and the cover under the trim on the driver

side. Refer to ⇒ Body Interior; Rep. Gr. 68 ; Storage Com‐

partments and Covers; Steering Column Trim Panel, Remov‐

ing and Installing .

Vehicles with Knee Airbag

– Remove the knee airbag bracket and the impact bolster. Refer

to ⇒ Body Interior ; Rep. Gr. 69 .

Continuation for All

– Remove the cable guide -2- from the steering column.

– Remove the footwell vents -3-. Refer to ⇒ Heating, Ventilation

and Air Conditioning; Rep. Gr. 80 ; Heating, Servicing; Vents,

Removing, Jetta from MY 2011 .

Vehicles without Knee Airbag

There are different ways of securing the impact bolster -1- in front

of the clutch pedal -2-.

Securing with Two Bolts

– Remove the impact bolster (two bolts).

36

Rep. Gr.30 - Clutch

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

Securing with One Bolt

– Remove the crash bolster -1- (1 bolt -2-).

Continuation for All

– Remove the damper -arrow- at the bottom of the mounting

bracket/clutch pedal, if equipped.

– Remove the washers -A- for the damper.

– Remove the damper.

1. Clutch Mechanism, Servicing

37

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– Push the damper near the upper nut -1- above the clutch pedal

-A- upward in the direction of -arrow-.

– Remove the nuts -1 and 2-.

The upper nut -1- is accessible between the relay panel and

steering column trim.

– Remove the mounting bracket -3-.

Installing

Install in reverse order of removal while. Note the following:

Note

♦ Replace the self-locking nuts.

♦ Replace the hose clamps

♦ Allocate all components according to the Parts Catalog.

Some vehicles have a damper -arrow- on the mounting bracket/

clutch pedal.

Vehicles without Knee Airbag

38

Rep. Gr.30 - Clutch

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

There are different ways of securing the impact bolster -1- in front

of the clutch pedal -2-.

Securing with Two Bolts

– Install the crash bolster -1- and tighten the 2 bolts to the tight‐

ening specification. Refer to

⇒ “1.5.1 Tightening Specifications”, page 40 .

Securing with One Bolt

– Install the crash bolster -1- and tighten the bolt -2- to the tight‐

ening specification. Refer to

⇒ “1.5.1 Tightening Specifications”, page 40 .

Continuation for All

– Attach the cable guide -2- to the steering column.

– Install the footwell vents -3-. Refer to ⇒ Heating, Ventilation

and Air Conditioning; Rep. Gr. 80 ; Heating, Servicing; Vents,

Removing, Jetta from MY 2011 .

Vehicles with Knee Airbag

– Install the knee airbag bracket and the impact bolster. Refer

to ⇒ Body Interior ; Rep. Gr. 69 .

Continuation for All

– Install the trim and the cover under the trim on the driver side.

Refer to ⇒ Body Interior; Rep. Gr. 68 ; Storage Compartments

and Covers; Steering Column Trim Panel, Removing and In‐

stalling .

– Install the hose/line assembly and pipe line -1- with the seal

-2- on the clutch master cylinder connection -4- until the clip

-3- audibly engages.

– Pull on the line to make sure it is secure.

– After removing the Hose Clamps - Up To 25mm - 3094- , bring

the return hose back to its original shape.

– Bleed the clutch mechanism. Refer to

⇒ “1.10 Clutch Mechanism, Bleeding”, page 48 .

– Install the battery tray and the battery. Refer to ⇒ Electrical

Equipment; Rep. Gr. 27 ; Battery; Battery, Removing and In‐

stalling .

– Install entire air filter housing if it is located near the battery.

Refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection System; Air

Filter Housing, Removing and Installing or ⇒ Rep. Gr. 24 ; Air

Filter; Air Filter Housing, Removing and Installing .

– Connect the battery and follow the steps for after connecting

the battery. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ;

Battery; Battery, Disconnecting and Connecting .

1. Clutch Mechanism, Servicing

39

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

1.5.1

Tightening Specifications

Component

Nm

25

Mounting bracket to bulkhead

♦ Replace the self-locking nuts.

Impact bolster to mounting bracket/steering

column (secured with two bolts)

10

20

Impact bolster to mounting bracket/steering

column (secured with one bolt)

♦ Replace the impact bolster bolts

1.6

Clutch Master Cylinder, Removing and

Installing

Special tools and workshop equipment required

♦ Clutch Pedal Pliers - T10005-

Removing

– Remove the mounting bracket. Refer to

⇒ “1.5 Mounting Bracket, Removing and Installing”, page 35 .

– Disengage the mount for the clutch master cylinder actuator

rod using the Clutch Pedal Pliers - T10005- .

– Place a spacer -A- between the clutch pedal and the stop and

then push the clutch pedal as far as the spacer.

♦ Length of spacer = approximately 40 mm (1.57 in.) (for exam‐

1

ple / " socket insert)

2

– Disengage the securing bracket -B- and remove the clutch

master cylinder from the mounting bracket in direction of

-arrow 1 and arrow 2-.

Installing

•

Move the clutch pedal up to the stop in its resting position.

40

Rep. Gr.30 - Clutch

Clutch -> 1.5 Mounting Bracket, Removing and Installing for Your Volkswagen Golf 4 Door Fifth Generation (2003-2008)

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