Clutch Hydraulic System: Description and Operation
Clutch System Overview
• Obtain the anti-theft code for the radio before disconnecting the battery.
• Turn off the ignition and disconnect the battery ground cable.
• Connect the battery and follow the procedures to be performed after connecting a battery.
• Lubricate all bearing areas and contact surfaces. For the correct grease, refer to the Parts Catalog.
I - => [ Clutch Pedal Overview ]
II - => [ Hydraulics Overview ]
III - Hydraulics Overview, Right Hand Drive (RHD) - Does Not Apply to the US/Canada
Clutch Pedal Overview
1 Bulkhead
• With a mount for the bracket.
2 Seal
• Always replace.
• Between the bracket and bulkhead.
• With self-adhesive.
• Attach to the bracket.
3 Bracket
• For the clutch pedal mounting.
• Some equipment versions have a damper.
• Removing and installing, refer to => [ Mounting Bracket ] Mounting Bracket.
4 Bolt
5 Over Center Spring
• Removing and installing, refer to => [ Over Center Spring ] Over Center Spring.
6 Bushing
7 Pin
8 Clutch Pedal
• Removing and installing, refer to => [ Clutch Pedal ] Clutch Pedal.
9 Mount
• To remove and install, disconnect the master cylinder from the clutch pedal. Refer to => [ Clutch Pedal ] Clutch Pedal.
10 Seal
• Always replace.
• Between the master cylinder and the bracket.
11 Master Cylinder
• Remove and install after removing the bracket. Refer to => [ Mounting Bracket ] Mounting Bracket.
12 Clutch Position Sensor (G476)
• Removing and installing, refer to => [ Clutch Position Sensor ] Service and Repair.
• Can be checked in "Guided Fault Finding" using the (VAS 5051).
• The clutch position sensor is called the clutch pedal switch (F36) in "Guided Fault Finding".
13 Clip
• The clip must be removed in order to remove/install the hose/line assembly.
14 Supply Hose
• Rubber
• Made of plastic as of 12.05.
15 Nut, Self Locking
• 25 Nm
• Always replace.
• Quantity: 3
• For securing the bracket to the bulkhead.
16 Nut
• 25 Nm
• Always replace.
17 Jounce Bumper
• For the clutch pedal.
Bracket with Damper - arrow -
Hydraulics Overview
1 Brake Fluid Reservoir
2 Spring Clamp
• Not on all vehicles.
3 Supply Hose
• Rubber
• Made of plastic as of 12.05.
4 Master Cylinder
• Removing and installing, refer to => [ Master Cylinder ] Service and Repair.
5 Clip
• The clip must be removed in order to remove/install the hose/line assembly.
6 Mount
• To remove and install, disconnect the master cylinder from the clutch pedal. Refer to => [ Clutch Pedal ] Clutch Pedal.
7 Clutch Pedal
• Removing and installing, refer to => [ Clutch Pedal ] Clutch Pedal.
8 Nut, Self Locking
• 25 Nm
• Always replace.
• Quantity: 3
• For securing the bracket to the bulkhead.
9 Seal/O-ring
• Installs onto the hose/line assembly connection.
• Install using brake fluid.
• Seal/O-ring suitable for the hose/line assembly connection.
• Allocation, refer to the Parts Catalog.
10 Hose/Line Assembly
• Allocation, refer to the Parts Catalog.
• To remove the hose/line assembly, remove the battery and battery tray.
11 Bracket
• Attached to the body.
12 Seal/O-ring
• Installs onto the hose/line assembly connection.
• Install using brake fluid.
• Seals/O-rings suitable for the hose/line assembly connection.
• Allocation, refer to the Parts Catalog.
13 Clip
• The clip must be removed in order to remove/install the hose/line assembly.
14 Clutch Slave Cylinder
• Removing and installing, refer to => [ Slave Cylinder ] Service and Repair.
15 Bolt
• 20 Nm
16 Bleed Valve
• Clutch system, bleeding. Refer to => [ Clutch System, Bleeding ] Service and Repair.
17 Dust Cap
18 Transmission
19 Bracket
20 Bolt
• 20 Nm
Seal/O-ring for the Hose/Line Assembly
• The seal/O-ring must be installed in the groove - arrow 1 - and - arrow 3 -.
Plastic Supply Hose
• The seals - 2 - must be inside the plastic supply hose- 1 -.