Volkswagen Golf / Golf GTI / Golf Variant. Manual - part 490

1.9

Bearing Bushing, Removing and Instal‐

ling

Removing
Disconnect the battery ground cable. Refer to ⇒  Electrical Equip‐

ment; Rep. Gr.  27 ; Battery; Battery, Disconnecting and Con‐

necting .
– Press together the retainers in the direction of -arrows- and

remove the studs -1- to the right side.

– Turn the valve fitter such that the openings -1- or pin -2- are

visible.

The openings -1- and the pin -2- face in the same direction.
– Remove the bearing bushing -A- from the openings -1-.

Installing
– Turn the valve fitter such that the openings -1- or pin -2- are

visible.

The openings -1- and the pin -2- face in the same direction.
– Fit the bearing bushing -A- in the openings -1- and rotate into

place.

– Use a new mounting pin to connect the valve fitter/clutch mas‐

ter cylinder to the clutch pedal.

– Connect the battery. Refer to ⇒  Electrical Equipment; Rep.

Gr.  27 ; Battery; Battery, Disconnecting and Connecting .

1.10

Clutch Master Cylinder, Removing and

Installing

Removing

Note

♦

Before replacing the clutch master cylinder due to an assumed

defect, perform the 

Guided Fault Finding

 Vehicle Diagno‐

sis Tester first.

♦

When working inside the footwell, cover the carpet with cloths

to protect it from leaking brake fluid.

– Remove the bracket. Refer to

⇒ “1.8 Mounting Bracket, Removing and Installing”, page 28

 .

– Remove the Clutch Position Sensor - G476- . Refer to

⇒ “1.15  Clutch Position Sensor G476 , Removing and Instal‐

ling”, page 37

 .

– Release retainers in the direction of -arrows- and remove

mounting pin -2-.

– Remove clutch master cylinder -1-.
Installing
Install in reverse order of removal. Note the following:
Replace mounting pin after removing.
– Install the bracket. Refer to

⇒ “1.8 Mounting Bracket, Removing and Installing”, page 28

 .

– Install the Clutch Position Sensor - G476- . Refer to

⇒ “1.15  Clutch Position Sensor G476 , Removing and Instal‐

ling”, page 37

 .

1.11

Clutch Slave Cylinder with Release

Bearing, Removing and Installing

Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm - VAG1331-

Note

♦

The clutch slave cylinder and the release bearing are a single

unit and are replaced together.

♦

Pay attention to the thread pitch on the bolts when cleaning

the threaded hole in the clutch housing.

Removing
• Transmission is removed.
– Open the clip -2- with a screwdriver or a pointed tool and re‐

move bleeder -4- from clutch slave cylinder -1-.

– Remove the bolts -arrows-.
– Remove the clutch slave cylinder together with the release

bearing -A-.

Installing
Install in the reverse order of removal while noting the following:
• Tighten the slave cylinder bolts in small increments only.
Otherwise, there is the danger that the tabs with the fastening

holes could break off.

– Check the O-ring -3- on the clutch slave cylinder for damage.
– Push the bleeder -4- onto the clutch slave cylinder connection

-1- until the clip -2- clicks into place.

– To check, pull on the bleeder.
– Install the transmission. Refer to

⇒ “2.2 Transmission, Installing”, page 92

 .

– Bleed the clutch mechanism. Refer to

⇒ “1.16 Clutch Mechanism, Bleeding”, page 37

 .

Tightening Specifications
♦ Clutch slave cylinder with release bearing to transmission.

Refer to

⇒ “1.4 Overview - Clutch Release Mechanism”, page 21

 .

1.12

Clutch Mechanism Lines, Removing

and Installing

Special tools and workshop equipment required
♦ Hose Clamps - Up To 25mm - 3094-
Removing
– Disconnect the battery ground cable. Refer to ⇒  Electrical

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

Connecting .

– Remove the air filter housing if the lines are not accessible.
Vehicles with a Turbo Diesel Engine
– Refer to ⇒  Engine Mechanical, Fuel Injection and Glow Plug;

Rep. Gr.  23 ; Air Filter; Air Filter Housing, Removing and In‐

stalling .

Vehicles with a Gasoline Engine
– Refer to ⇒  Engine Mechanical, Fuel Injection and Ignition;

Rep. Gr.  24 ; Air Filter; Air Filter Housing, Removing and In‐

stalling .

Continuation for All
– Remove the battery and the battery tray. Refer to ⇒  Electrical

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

Connecting .

Caution

Danger of leaking brake fluid.

♦ Be careful not to get any brake fluid on the longitudinal

member or on the transmission when performing the fol‐

lowing work. If it does, clean the area thoroughly.

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

– Unclamp the supply hose -2- to the clutch master cylinder with

a -3094- .

Note

♦

A slight deformation of the supply hose remains after the

-3094- have been unclamped.

♦

The supply hose is therefore not defective.

♦

After removing the -3094- , the supply hose must be formed

back into its original shape.

– Remove clip for hose/line assembly -1- all the way and remove

hose/line assembly.

– Seal off openings.

– Remove the clip -arrow- all the way and then remove the hose/

line assembly -A- from the bleeder.

Ignore item -B-.
– Seal the open lines and connections with clean plugs if nec‐

essary from the -VAS6122- .

– Free up the hose/line assembly and remove it.
Installing
Install in reverse order of removal. Note the following:

– Connect hose/line assembly -1- with clutch master cylinder.
– Pull on the line to make sure it is secure.