Volkswagen Golf / Golf GTI / Golf Variant. Manual - part 565

– Remove the clutch master cylinder return hose and seal with

the Sealing Tool - T10249/1- .

Note

When working inside the footwell, cover the carpet with cloths to

protect it from leaking brake fluid.

– Disconnect the connector -2- from the Clutch Position Sensor

- G476- .

– Remove nuts -arrows- and bracket -1-.

Installing
Install in reverse order of removal. Note the following:
– Replace self-locking nuts and clutch master cylinder seals af‐

ter removing them.

– Insert the crash bolster -1- and tighten the bolt -2-. Refer to ⇒ 

Body Interior; Rep. Gr.  70 ; Instrument Panel Central Tube;

Overview - Instrument Panel Central Tube .

– Install the Data Bus on Board Diagnostic Interface - J533- .

Refer to ⇒  Electrical Equipment; Rep. Gr.  97 ; Control Mod‐

ules; Component Location Overview - Control Modules .

– Install the driver side footwell vent. Refer to ⇒  Heating, Ven‐

tilation and Air Conditioning; Rep. Gr.  87 ; Air Routing; Driver

Side Footwell Vent, Removing and Installing .

Vehicles with a Knee Airbag
– Install the driver side knee airbag. Refer to ⇒  Body Interior;

Rep. Gr.  69 ; Knee Airbags; Overview - Knee Airbag .

Note

The battery will be installed and connected later.

Continuation for All

Pro

te

c

t

ed

  b

y

  co

p

y

rig

h

t. 

C

o

p

y

in

g

  fo

r 

pr

iv

a

t

e

 o

r

 c

o

m

m

e

r

c

ia

l 

p

u

rp

o

s

e

s

,

 i

n

 p

a

rt

o

r i

n

 w

h

o

le

, 

is

 n

o

t

 p

e

r

m

it

t

e

d

 u

n

l

e

s

s

 a

ut

ho

r

i

s

ed

 b

y

 V

olk

sw

a

ge

n AG

.

 

V

olk

s

w

a

g

en

 AG do

es 

n

ot g

uar

ante

e

 or a

c

c

ep

t

 a

ny

 

li

a

b

i

li

t

y

 w

ith

 r

e

s

p

e

c

t

 t

o

 

th

e

 c

o

rr

e

c

t

n

e

s

s

 

o

f

in

fo

r

m

a

tio

n

 in

 th

is

 d

o

c

um

en

t.

C

o

py

rig

ht b

y

 

V

olk

sw

a

ge

n

 

A

G.

– Connect hose/line assembly -1- with connection

⇒ Fig. ““Disconnect and Connect Clutch Mechanism Wires”“ ,

page 16

 .

– Connect the supply hose -2- to the clutch master cylinder.
• After removing the Hose Clamp up to 25 mm - 3094- , the

supply hose must be formed back into its original shape.

– Bleed the clutch mechanism. Refer to

⇒ “1.13 Clutch Mechanism, Bleeding”, page 33

 .

Vehicles with a Knee Airbag
– Install drivers side knee airbag and connect the battery. Refer

to ⇒  Body Interior; Rep. Gr.  69 ; Knee Airbags; Overview -

Knee Airbag and ⇒  Electrical Equipment; Rep. Gr.  27 ;

Battery; Battery, Disconnecting and Connecting .

Vehicles without Knee Airbag
– Install and connect the battery. Refer to ⇒  Electrical Equip‐

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

Connecting .

Tightening Specifications
♦ Mounting bracket to bulkhead. Refer to

⇒ “1.2 Overview - Pedal Assembly”, page 13

 .

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 Diag‐

nostic Tester first.

♦

When working inside the footwell, cover the carpet with cloths

to protect it from leaking brake fluid.

– Remove the bracket. Refer to

⇒ “1.9 Mounting Bracket, Removing and Installing”, page 26

 .

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

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

ling”, page 34

 .

– Release retainers in direction of -arrows- and remove mount‐

ing 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

⇒ “1.9 Mounting Bracket, Removing and Installing”, page 26

 .

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

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

ling”, page 34

 .

1.11

Clutch Slave Cylinder, Removing and

Installing

Special tools and workshop equipment required
♦ Hose Clamps - Up To 25 mm - 3094-
♦ Torque Wrench 1331 5-50Nm - VAG1331-

Caution

This procedure contains mandatory replaceable parts. Refer

to component overview prior to starting procedure.

Mandatory Replacement Parts
♦ Nuts - Transmission Support to Transmission
Removing

Note

♦

Before replacing the clutch master cylinder due to an assumed

defect, perform the 

Guided Fault Finding

 Vehicle Diag‐

nostic Tester first.

♦

If the clutch slave cylinder is removed from the transmission

with the hose/line assembly connected, do not operate (de‐

press) clutch pedal any more. Otherwise, the pistons are

pushed out of the clutch slave cylinder and thus damaged.

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

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

necting .
– Remove the entire air filter housing if it makes the clutch slave

cylinder inaccessible. Refer to ⇒  Engine Mechanical, Fuel In‐

jection and Ignition; Rep. Gr.  24 ; Air Filter; Air Filter Housing,

Removing and Installing .

– Remove the transmission support -arrows-.
– Remove the battery and the battery tray if necessary. Refer to

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

moving and Installing .

– Place a lint-free cloth under the clutch slave cylinder.
– Release the clamp -A- with a screwdriver and remove the

hose/line assembly -B- from the connection.

– Remove the hose/line assembly -B- from the clutch slave cyl‐

inder and seal off the openings.

– Remove the bolts -arrows- and the clutch slave cylinder.

Caution

There is a risk of contamination from the leaking brake fluid.

♦ When the hose/line assembly is separated from the con‐

nection, do not press the clutch pedal.

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

Note

♦

Lubricate all bearing areas and contact surfaces.

♦

Allocation of the grease. Refer to the Parts Catalog.

– Install the clutch slave cylinder -A- and secure with the bolts

-arrows-.

– Connect the hose/line assembly -B-

⇒ Fig. ““Disconnect and Connect Clutch Mechanism Wires”“ ,

page 16

 .

– Bleed the clutch mechanism. Refer to

⇒ “1.13 Clutch Mechanism, Bleeding”, page 33

 .

– Install the air filter housing if it was removed earlier. Refer to

⇒  Engine Mechanical, Fuel Injection and Ignition; Rep. Gr. 

24 ; Air Filter; Air Filter Housing, Removing and Installing .

– Install the battery and the battery tray if they were removed

earlier. Refer to ⇒  Electrical Equipment; Rep. Gr.  27 ; Battery;

Overview - Battery .

Tightening Specifications

♦ Refer to

⇒ “1.4 Overview - Clutch Release Mechanism”, page 18

 .

♦ Transmission support to transmission bracket and transmis‐

sion -arrows-. Refer to

⇒ “3.1 Overview - Subframe Mount”, page 87

 .

1.12

Clutch Mechanism Lines, Removing

and Installing

Special tools and workshop equipment required