Clutch Pedal Assembly: Service and Repair

Pedal cluster, assembly overview





1. Mounting bracket
^ Detach steering column from steering box before removing
2. Pivot pin
^ For clutch pedal and brake pedal
^ Installation position: groove (arrow) towards clutch pedal
3. Locking clip
4. Hexagon socket head bolt, 25 Nm
5. Brake pedal
6. Clutch pedal
^ Removing and installing
7. Pin
^ Clip onto clutch pedal
8. Locking clip
9. Master cylinder
^ Removing and installing
^ Do not operate clutch pedal after slave cylinder has been removed.
10. Hexagon socket head bolt, 20 Nm
11. Mounting
^ Insert in mounting bracket with over-center spring
12. Over-center spring
^ Allocation
^ Remove and install with clutch pedal
13. Hexagon socket head bolt, 5 Nm
^ Secures clutch and brake pedal pivot pin
14. Seal
^ Must not be removed
15. Torx bolt - 25 Nm
^ Also secures the brake master cylinder with brake servo

Clutch pedal and over-center spring, removing and installing
Removing
- Remove driver's side storage compartment:





Notes:
^ For the following procedures, make sure that the clutch pedal does not press out vent valve (arrow) from securing clip, since the thread of the switch would be damaged and the switch would have to be replaced.
^ To ensure proper securing, the vent valve (arrow) may only be installed once.





- Detach clutch pedal from master cylinder. To do this, unclip pin using a screwdriver (arrow -1-) and pull out pin (arrow -2-).
- Press clutch pedal securing clip off pivot pin with a screwdriver.





- Unscrew bolt (arrow).
- Press clutch and brake pedal pivot pin out to the right, until the clutch pedal can be removed.
- If necessary press brake pedal securing clip off pivot pin with a screwdriver.
- Take out clutch pedal and over-center spring.

Installing
Installation is carried out in the reverse order, when doing this note the following:





- Align the clutch pedal/brake pedal pivot pin so that it protrudes out of mounting bracket at the clutch pedal side (arrow).
- First hook the clutch pedal into the over-center spring, then fit onto pivot pin.
- Connect clutch pedal to master cylinder. Clip pin onto clutch pedal.





- Do not tighten bolt (arrow) until both securing clips have been fitted on the clutch pedal/brake pedal pivot pin.





- Check adjustment of switch -1- via the clutch pedal as follows:
^ Switch -1- must sit completely against clutch pedal -3- and must be completely activated.
^ Adjustment specification: The gap measurement-a- between securing clip and mounting bracket -2- or gap measurement -b- at switch -1- be no larger than 0.5 mm.
^ To adjust, clamp must be held and switch -1- must be turned.

Note: To ensure proper securing, the switch may only be installed once.