Clutch -> 1.8 Overview - Hydraulics for Your 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  
– Disengage the clamp -2- using a screwdriver or a pointed tool  
and pull the clutch master cylinder out until it stops.  
– Remove the hose/line assembly -1- and the pipe from the  
clutch master cylinder and seal it off.  
– Disconnect the connector -4-.  
– Unclip the Clutch Position Sensor - G476- from the clutch  
master cylinder -arrow- and remove it.  
Note  
Ignore item -3-.  
Installing  
Install in reverse order of removal while. Note the following:  
Note  
Replace the hose clamps  
Allocate all components according to the Parts Catalog.  
If the Hose/Line Assembly was Removed  
– Install the hose/line assembly -1- and the pipe line with the  
seal -2- on the clutch master cylinder connection -4- until the  
clip -3- audibly engages.  
– Pull on the hose/line assembly and pipe to make sure it is se‐  
cure.  
– 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 .  
1.8  
Overview - Hydraulics  
1. Clutch Mechanism, Servicing  
43  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
1 - Brake Fluid Reservoir  
2 - Spring Clamp  
❑ Not on all vehicles  
3 - Hose  
❑ Rubber  
❑ As of 12.2005, made of  
plastic. Refer to  
⇒ Fig. ““Plastic  
Hose -1- ”“ , page 46  
4 - Clutch Master Cylinder  
❑ Removing and instal‐  
ling. Refer to  
⇒ “1.6 Clutch Master  
Cylinder, Removing and  
Installing”, page 40 .  
5 - Clamp  
❑ To remove and install  
the hose/line assembly  
or pipe, pull the clamp all  
the way out.  
❑ On some clutch master  
cylinders, it is pulled out  
on the side  
6 - Seal/O-Ring  
❑ Install on the line con‐  
nection  
❑ Install with brake fluid  
❑ Seals/O-rings suitable  
for the line connection  
version. Refer to  
⇒ Fig. ““Sealing Rings/  
O-Rings for Hose/Line  
Assembly or Pipe”“ ,  
page 45  
❑ Allocation. Refer to the Parts Catalog.  
7 - Support  
❑ To remove and install, disconnect the clutch master cylinder from the clutch pedal. Refer to  
⇒ “1.4 Clutch Pedal, Removing and Installing”, page 29 .  
8 - Clutch Pedal  
❑ Removing and installing. Refer to ⇒ “1.4 Clutch Pedal, Removing and Installing”, page 29 .  
9 - Hex Nut  
❑ 25 Nm  
❑ Self-locking  
❑ Quantity: 3  
❑ For the mounting bracket to the bulkhead  
❑ Replace after removing  
10 - Hose/Line Assembly  
❑ Allocation. Refer to the Parts Catalog.  
❑ To remove, remove the battery and battery tray. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery;  
Battery, Removing and Installing .  
❑ Removing and installing. Refer to  
⇒ “2.3 Hose/Line Assembly or Pipe, Removing and Installing”, page 53 .  
11 - Bracket  
❑ For hose/line assembly -item 10- ⇒ Item 10 (page 44)  
44  
Rep. Gr.30 - Clutch  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
❑ Attached to the body  
❑ Covered by the assembly mounting  
❑ Bracket differentiation. Refer to ⇒ Fig. ““Bracket Differentiation”“ , page 46  
12 - Line  
❑ Allocation. Refer to the Parts Catalog.  
❑ To remove, remove the battery and battery tray. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery;  
Battery, Removing and Installing .  
❑ Removing and installing. Refer to  
⇒ “2.3 Hose/Line Assembly or Pipe, Removing and Installing”, page 53 .  
13 - Bracket  
❑ For the pipe -item 12- ⇒ Item 12 (page 45)  
❑ Attached to the body  
❑ Covered by the assembly mounting  
❑ Bracket differentiation. Refer to ⇒ Fig. ““Bracket Differentiation”“ , page 46  
14 - Seal/O-Ring  
❑ Install on the line connection  
❑ Install with brake fluid  
❑ Seals/O-rings suitable for the line connection version. Refer to  
⇒ Fig. ““Sealing Rings/O-Rings for Hose/Line Assembly or Pipe”“ , page 45  
❑ Allocation. Refer to the Parts Catalog.  
15 - Bleeder  
❑ Removing and installing. Refer to  
⇒ “2.1 Line Assembly and Bleeder on the Clutch Slave Cylinder, Removing and Installing”, page 52 .  
16 - Clamp  
❑ To remove and install the hose/line assembly or pipe and the bleeder, pull the clip all the way out.  
17 - Breather Valve  
❑ Bleed clutch mechanism. Refer to ⇒ “1.10 Clutch Mechanism, Bleeding”, page 48 .  
18 - Dust Cap  
19 - Clutch Slave Cylinder  
❑ The gasket can only be replaced when the transmission is removed.  
❑ Removing and installing. Refer to  
⇒ “2.2 Clutch Slave Cylinder with Release Bearing, Removing and Installing”, page 52 .  
20 - Transmission  
Sealing Rings/O-Rings for Hose/Line Assembly or Pipe  
Item  
1
Line Connection Version  
Line connection with a groove all the way around  
-arrow 1-  
2
3
Line connection with a shoulder -arrow 2-  
Line connection with a shoulder -arrow 2- and with  
a groove all the way around -arrow 3-  
1. Clutch Mechanism, Servicing  
45  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
Plastic Hose -1-  
The seals -2- must be inside the hose.  
Bracket Differentiation  
Dimension “a” mm  
Line Version  
Line  
Hose/Line Assembly  
8
6
1.9  
Overview - Hydraulics, RHD  
46  
Rep. Gr.30 - Clutch