Volkswagen Golf / Golf GTI / Golf Variant. Manual - part 491

– Push the hose/line assembly -4- with the O-ring -3- onto the

bleeder connection -1- until the clip -2- audibly locks into place.

– Pull on the line to make sure it is secure.
• After removing the -3094- , the return hose -2- (⇒ previous

illustration) must be formed back into its original shape.

– Bleed the clutch mechanism. Refer to

⇒ “1.16 Clutch Mechanism, Bleeding”, page 37

 .

– Install the air filter housing.
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
– Install the battery tray, battery and the battery cover. Refer to

⇒  Electrical Equipment; Rep. Gr.  27 ; Battery; Battery, Dis‐

connecting and Connecting .

1.13

Bleeder, Removing and Installing

Hose/Line Assembly or Pipe -4- on Bleeder -1-, Removing and

Installing
– To remove, release the clip -2- with a screwdriver or a pointed

tool and pull off hose/line assembly or pipe -4- from the bleeder

-1-.

– To install, press hose/line assembly or pipe with new O-ring

-3- onto the bleeder connection, until clip audibly engages.

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

Removing and Installing the Bleeder -4- from the Clutch Slave

Cylinder
– To remove, release the clip -2- with a screwdriver or a pointed

tool and remove the bleeder -4- from the clutch slave cylinder

-1-.

– To install, check the O-ring -3- on the clutch slave cylinder.

Press in the bleeder at the clutch slave cylinder connector until

the clip -2- engages audibly.

– To check, pull on the bleeder.
– Bleed the clutch mechanism. Refer to

⇒ “1.16 Clutch Mechanism, Bleeding”, page 37

 .

1.14

Clutch Master and Clutch Slave Cylin‐

der, Checking

Before replacing the clutch master cylinder due to an assumed

defect, perform the 

Guided Fault Finding

 with the Vehicle Di‐

agnosis Tester first.

1.15

Clutch Position Sensor - G476- , Re‐

moving and Installing

Removing
– Move the driver seat as far back as possible.
– Disconnect the connector -arrow- from the Clutch Position

Sensor - G476- .

– Release the Clutch Position Sensor - G476- -2- tab on the

clutch master cylinder -1- in the direction of -arrow- and re‐

move it.

Installing
Install in reverse order of removal. Note the following:
• The tab -arrow- on the Clutch Position Sensor - G476- must

remain intact.

• The Clutch Position Sensor - G476- must engage audibly.

1.16

Clutch Mechanism, Bleeding

Special tools and workshop equipment required
♦ Brake Charger/Bleeder Unit - VAS5234-
♦ Bleeder Hose (670 mm) - VAG1238/B3-

Note

♦

The system must be bled after working on the hydraulic clutch

mechanism.

♦

Make sure no brake fluid gets on the transmission when per‐

forming the following work.

♦

It is not necessary to pre-fill the system.

♦

Before bleeding, fill the brake fluid reservoir to the “Max” mark‐

ing with brake fluid.

♦

The clutch pedal is in the neutral position and is not pressed.

♦

Brake fluid: Allocation. Refer to the Parts Catalog.

– Remove the air filter housing if it makes the bleeder inacces‐

sible.

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 Instal‐

ling .
Vehicles with a Gasoline Engine
Refer to ⇒  Engine Mechanical, Fuel Injection and Ignition; Rep.

Gr.  24 ; Air Filter; Air Filter Housing, Removing and Installing .
Continuation for All
– Return clutch pedal to the rest position.
– Remove cap from the bleed valve -arrow-.
– Connect the -VAS5234- .
If necessary use the -VAG1238/B3- .
– Connect the bleed hose -A- with the collector bottle pressure

hose.

– Turn on the -VAS5234- .
• Working pressure 2.0 bar (29 psi).
– Open the bleed valve approximately 1/4 turn.
– Move the clutch pedal manually 15 to 20 time very quickly from

stop to stop.

– Close the bleed valve and turn off the bleed unit.
– After completing the bleeding procedure, and the pressure has

dropped from 2 bar (29 psi), operate the clutch pedal an ad‐

ditional 10 times by foot.

– Install the air filter housing.
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
♦ Close the bleed valve. Refer to

⇒ “1.3 Overview - Clutch Hydraulics”, page 17

 .

1.17

Clutch Release Mechanism, Servicing

Special tools and workshop equipment required
♦ Torque Wrench 5-50Nm - VAG1331-
♦ Clutch Disc Shaft Spline Lubricant - G 000 100-
• The transmission is removed.

– Remove and attach the clutch slave cylinder with the release

bearing -arrows-.

Clutch Slave Cylinder -A- with Divided Supply Line
The supply line is divided in area with -arrows- on some clutch

slave cylinders
Allocation. Refer to the Parts Catalog.

Release Bearing with Additional Plastic Washer
How to recognize: Tabs -arrow- on the plastic washer.

Only for Release Bearings with Additional Plastic Washer; Where

the Pressure Plate Diaphragm Spring -arrows- are a Slightly Low‐

er Installation Height
• Install the release bearing with additional plastic washer and

the pressure plate diaphragm spring with a slightly lower in‐

stallation height.

Allocation. Refer to the Parts Catalog.
– 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
♦ Refer to

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

 .