Get Clutch -> 1 Clutch Mechanism, Servicing 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

30 – Clutch

1

Clutch Mechanism, Servicing

⇒ “1.1 Overview”, page 21

⇒ “1.2 Overview - Pedal Cluster”, page 23

⇒ “1.3 Over-Center Spring, Removing and Installing”, page 24

⇒ “1.4 Clutch Pedal, Removing and Installing”, page 29

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

⇒ “1.6 Clutch Master Cylinder, Removing and Installing”,

page 40

⇒ “1.7 Clutch Position Sensor G476 , Removing and Installing”,

page 41

⇒ “1.8 Overview - Hydraulics”, page 43

⇒ “1.10 Clutch Mechanism, Bleeding”, page 48

1.1

Overview

Note

♦ Get the anti-theft code for the radio before disconnecting the battery.

♦ Disconnect the battery ground cable. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Battery,

Disconnecting and Connecting .

♦ Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and Connecting when con‐

necting the battery.

♦ Lubricate all bearing areas and contact surfaces.

♦ Refer to the Parts Catalog for the grease allocation.

1. Clutch Mechanism, Servicing

21

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

6-Speed Manual Transmission 02Q - Edition 05.2013

I -

⇒ “1.2 Overview - Pedal Clus‐

ter”, page 23 .

II -

⇒ “1.8 Overview - Hydraulics”,

page 43 .

III - Overview Hydraulics, RHD

22

Rep. Gr.30 - Clutch

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

6-Speed Manual Transmission 02Q - Edition 05.2013

1.2

Overview - Pedal Cluster

1 - Bulkhead

❑ With a mount for the

mounting bracket

2 - Seal

❑ Replace after removing

❑ Between the mounting

bracket and bulkhead

❑ Self-adhesive

❑ Attached to the mount‐

ing bracket

3 - Mounting Bracket

❑ For the clutch pedal

mount

❑ Some versions have a

damper. Refer to

⇒ Fig. ““Mounting

Bracket with

Damper -arrow- ”“ ,

page 24

❑ Removing and instal‐

ling. Refer to

⇒ “1.5 Mounting Brack‐

et, Removing and Instal‐

ling”, page 35 .

4 - Bolt

5 - Over-Center Spring

❑ Removing and instal‐

ling. Refer to

⇒ “1.3 Over-Center

Spring, Removing and

Installing”, page 24 .

6 - Bearing Bushing

7 - Mounting Pin

8 - Clutch Pedal

❑ Removing and installing. Refer to ⇒ “1.4 Clutch Pedal, Removing and Installing”, page 29 .

9 - 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 .

10 - Seal

❑ Replace after removing

❑ Between the clutch master cylinder and the mounting bracket

11 - Clutch Master Cylinder

❑ Removing and installing after removing the mounting bracket. Refer to

⇒ “1.6 Clutch Master Cylinder, Removing and Installing”, page 40

12 - Clutch Position Sensor - G476-

❑ Removing and installing. Refer to

⇒ “1.7 Clutch Position Sensor G476 , Removing and Installing”, page 41 .

❑ Can be checked in “Guided Fault Finding” using Vehicle Diagnostic Tester .

❑ The Clutch Position Sensor - G476- is called the Clutch Pedal Switch - F36- in “Guided Fault Finding”.

1. Clutch Mechanism, Servicing

23

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

6-Speed Manual Transmission 02Q - Edition 05.2013

13 - Clamp

❑ To remove and install the hose/line assembly or pipe, pull the clamp all the way out.

14 - Hose

❑ Rubber

❑ Made of plastic from 12/2005. Refer to ⇒ Fig. ““Plastic Hose -1- ”“ , page 46

15 - Hex Nut

❑ 25 Nm

❑ Self-locking

❑ Quantity: 3

❑ For the mounting bracket to the bulkhead

❑ Replace after removing

16 - Hex Nut

❑ 25 Nm

❑ Replace after removing

17 - Stop

❑ For the clutch pedal

Mounting Bracket with Damper -arrow-

1.3

Over-Center Spring, Removing and In‐

stalling

⇒ “1.3.1 Tightening Specifications”, page 29

Special tools and workshop equipment required

♦ Over-Center Spring Assembly Tool - T10178-

Removing

Vehicles with Knee Airbag

Note

The knee airbag is installed above the foot pedal assembly.

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

anti-theft code.

24

Rep. Gr.30 - Clutch

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

6-Speed Manual Transmission 02Q - Edition 05.2013

– Disconnect the battery ground cable. Refer to ⇒ Electrical

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

Connecting .

Continuation for All

– Move the driver seat all the way back and raise the steering

wheel to the highest position.

– 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 crash bolster -1- (two bolts).

Securing with One Bolt

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

Continuation for All

1. Clutch Mechanism, Servicing

25

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

6-Speed Manual Transmission 02Q - Edition 05.2013

– 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.

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

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

26

Rep. Gr.30 - Clutch

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

6-Speed Manual Transmission 02Q - Edition 05.2013

– Remove the nut -2- and the bolt -5- and then remove the clutch

pedal -1- from the mounting bracket -3-.

Note

The clutch pedal remains engaged in the clutch master cylinder

actuator rod.

– Move the clutch pedal downward and remove the over-center

spring -4- from the mounting bracket.

Installing

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

Note

Replace the self-locking nuts.

– Install the over-center spring -2- into the mounting bracket

from the top and hold the end of the spring in its installed po‐

sition using the Over-Center Spring Assembly Tool - T10178- .

•

The mounting area -arrow- for the clutch pedal pivot pin -A-

must be positioned vertically.

– Insert the clutch pedal pivot pin -A- into the mounting cup of

the over-center spring.

– Press the clutch pedal slightly, push the bolt through and tight‐

en the self-locking nut, tightening specification. Refer to

⇒ “1.3.1 Tightening Specifications”, page 29 .

1. Clutch Mechanism, Servicing

27

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

6-Speed Manual Transmission 02Q - Edition 05.2013

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

clutch pedal.

– Bring the damper back into the installation position.

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

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

ening specification. Refer to

⇒ “1.3.1 Tightening Specifications”, page 29 .

Securing with One Bolt

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

ening specification. Refer to

⇒ “1.3.1 Tightening Specifications”, page 29 .

Continuation for All

28

Rep. Gr.30 - Clutch

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

6-Speed Manual Transmission 02Q - Edition 05.2013

– 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 .

– If disconnected, connect the battery. Refer to ⇒ Electrical

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

Connecting .

1.3.1

Tightening Specifications

Component

Nm

25

Clutch pedal to mounting bracket

♦ 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

1.4

Clutch Pedal, Removing and Installing

⇒ “1.4.1 Tightening Specifications”, page 34

Special tools and workshop equipment required

♦ Clutch Pedal Pliers - T10005-

♦ Over-Center Spring Assembly Tool - T10178-

Removing

Vehicles with Knee Airbag

Note

The knee airbag is installed above the foot pedal assembly.

– 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 .

Continuation for All

– Move the driver seat all the way back and raise the steering

wheel to the highest position.

– 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 .

1. Clutch Mechanism, Servicing

29

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

6-Speed Manual Transmission 02Q - Edition 05.2013

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 crash bolster -1- (two bolts).

Securing with One Bolt

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

Continuation for All

30

Rep. Gr.30 - Clutch

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

6-Speed Manual Transmission 02Q - Edition 05.2013

– 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.

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

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

1. Clutch Mechanism, Servicing

31

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

6-Speed Manual Transmission 02Q - Edition 05.2013

– Remove the nut -2- and the bolt -5- and then remove the clutch

pedal -1- from the mounting bracket -3-.

– Move the clutch pedal foreword and remove the over-center

spring -4- from the mounting bracket.

– Release clutch pedal from clutch master cylinder with Clutch

Pedal Pliers - T10005- .

– Remove the clutch pedal.

Installing

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

Note

Replace the self-locking nuts.

– Install the mount -2- on the clutch master cylinder actuator rod

-1-.

– Press mount until it engages audibly in notch on clutch pedal

-3-.

32

Rep. Gr.30 - Clutch

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

6-Speed Manual Transmission 02Q - Edition 05.2013

– Install the over-center spring -2- into the mounting bracket

from the top and hold the end of the spring in its installed po‐

sition using the Over-Center Spring Assembly Tool - T10178- .

•

The mounting area -arrow- for the clutch pedal pivot pin -A-

must be positioned vertically.

– Insert the clutch pedal pivot pin -A- into the mounting cup of

the over-center spring.

– Press the clutch pedal slightly, push the bolt through and tight‐

en the self-locking nut to the tightening specification. Refer to

⇒ “1.4.1 Tightening Specifications”, page 34 .

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

clutch pedal.

– Bring the damper back into the installation position.

Vehicles without Knee Airbag

1. Clutch Mechanism, Servicing

33

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

⇒ “1.4.1 Tightening Specifications”, page 34 .

Securing with One Bolt

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

ening specification. Refer to

⇒ “1.4.1 Tightening Specifications”, page 34 .

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 .

– Connect the battery and follow the steps for after connecting

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

Battery; Battery, Disconnecting and Connecting .

1.4.1

Tightening Specifications

Component

Nm

25

Clutch pedal to mounting bracket

♦ 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

34

Rep. Gr.30 - Clutch

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

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

6-Speed Manual Transmission 02Q - Edition 05.2013

– Install the mount -2- on the clutch master cylinder actuator rod

-1-.

– 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

– Install the clutch master cylinder on the mounting bracket in

direction of -arrow 1 and arrow 2-.

– Push the clutch master cylinder actuator rod -1- in direction of

-arrow- until the mount -2- clicks into the place in the clutch

pedal.

– Install the mounting bracket. Refer to

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

1.7

Clutch Position Sensor - G476- , Re‐

moving and Installing

Special tools and workshop equipment required

♦ Hose Clamps - Up To 25mm - 3094-

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

1. Clutch Mechanism, Servicing

41

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

6-Speed Manual Transmission 02Q - Edition 05.2013

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 .

If a Hose/Line Assembly -1- with a Round Component Is Installed

Directly below the Clutch Master Cylinder, Hose/Line Assembly

Must Be Removed.

Note

While performing the following work, make sure no brake fluid

comes into contact with the longitudinal member or the transmis‐

sion. If it does, clean the area thoroughly.

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

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

Clamps - Up To 25mm - 3094- .

42

Rep. Gr.30 - Clutch

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

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

6-Speed Manual Transmission 02Q - Edition 05.2013

1 - Brake Fluid Reservoir

2 - Seal

❑ For the plastic hose

❑ The seals must be in‐

side the hose.

3 - Hose

❑ Made of plastic. Refer to

⇒ Fig. ““Plastic

Hose -1- ”“ , page 46

❑ May also be made of

rubber

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 line, remove the clip

up to the stop

❑ 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 - Bracket

❑ Attached to the body

❑ covered by the assembly mounting

11 - Line

❑ The pipe line and pipe/hose line -item 13- ⇒ Item 13 (page 48) may also be a single piece.

❑ Removing and installing. Refer to

⇒ “2.3 Hose/Line Assembly or Pipe, Removing and Installing”, page 53 .

❑ Allocation. Refer to the Parts Catalog.

1. Clutch Mechanism, Servicing

47

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

6-Speed Manual Transmission 02Q - Edition 05.2013

❑ To remove, remove the battery and battery tray. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery;

Battery, Removing and Installing .

12 - 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.

13 - Hose/Line Assembly

❑ The pipe line and pipe/hose line -item 11- ⇒ Item 11 (page 47) may also be a single piece.

❑ Removing and installing. Refer to

⇒ “2.3 Hose/Line Assembly or Pipe, Removing and Installing”, page 53 .

❑ 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 .

14 - Bracket

❑ Attached to the body

15 - Seal/O-Ring

❑ Install on the line connection

❑ Install with brake fluid

❑ Seals/O-rings suitable for the line connection material. Refer to

⇒ Fig. ““Sealing Rings/O-Rings for Hose/Line Assembly or Pipe”“ , page 45

❑ Allocation. Refer to the Parts Catalog.

16 - Clamp

❑ To remove and install the hose/line assembly or 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 - Bleeder

❑ Removing and installing. Refer to

⇒ “2.1 Line Assembly and Bleeder on the Clutch Slave Cylinder, Removing and Installing”, page 52 .

20 - Seal/O-Ring

❑ Install on the line connection

❑ Install with brake fluid

❑ Seals/O-rings suitable for the line connection material

⇒ Fig. ““Sealing Rings/O-Rings for Hose/Line Assembly or Pipe”“ , page 45

❑ Allocation. Refer to the Parts Catalog.

21 - 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 .

22 - Transmission

1.10

Clutch Mechanism, Bleeding

Special tools and workshop equipment required

♦ Brake Charger/Bleeder Unit - VAS5234-

48

Rep. Gr.30 - Clutch

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

6-Speed Manual Transmission 02Q - Edition 05.2013

Note

It is not necessary to pre-fill the system.

Brake fluid specification. Refer to ⇒ Brake System; Rep. Gr. 47 ;

Hydraulic System .

– 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 .

– Connect the Brake Charger/Bleeder Unit - VAS5234- .

It is necessary to use the Bleeder Hose (670 mm) - VAG1238/B3-

to bleed.

– Connect the bleeder hose to the brake bleeder unit collector

bottle.

– Connect bleeder hose -A- to bleeder -arrow-.

– Apply 2.0 bar (29 psi) pressure to the system.

– Open the breather valve approximately 1/4 to 1/2 turn.

– Move the clutch pedal 15 to 20 times rapidly by hand from stop

to stop.

– Close breather valve and switch bleeder device off.

– After completing the bleeding procedure, and the pressure has

dropped from 2.0 bar (29 psi), operate the clutch pedal an ad‐

ditional 10 times by foot.

– If it was removed earlier install the complete air filter housing.

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 .

1. Clutch Mechanism, Servicing

49

Clutch -> 1 Clutch Mechanism, Servicing for Your Volkswagen Golf 4 Door Fifth Generation (2003-2008)

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