1996 AUDI A4 01A Transmission Clutch Mechanism Service Workshop Manual

30-15

- Remove
driver's side
storage
compartment
Repair Manual,
Body Interior, Repair Group 68


- Remove switch above clutch pedal if installed
Page 30
-7

Installing
Installation is the reverse of removal, note the following: - Unclip pin using screwdriver (arrow -1-), pull out pin (arrow -2-), and
detach clutch pedal from clutch master cylinder.
- Unbolt clutch master cylinder from passenger compartment.

- When replacing clutch master cylinder, check dimension -a- on ball
head and adjust if necessary.

Dimension -a- = 165 0.5 mm (6.496 0.020 in.)
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30-16

- Connect clutch master cylinder to clutch pedal.
Secure pin and locking plate on clutch pedal.

To install E-box in plenum chamber: - Tighten line fitting -B- to clutch master cylinder to 15 Nm (11 ft lb).
- Slide hose -A- onto brake fluid reservoir up to stop.
- Bleed hydraulic clutch system after installing clutch master cylinder
Page 30
-17
.

- Always replace seal -C-.
- Make sure seal is positioned properly, and does not cover opening or
stepped metal edge.
- Install E-box by hand and evenly tighten nuts -A- to 4 Nm (35 in. lb)
(i.e. imprint on E-box cover).
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30-17

Clutch system, bleeding


Special tools and equipment

VAG1238B brake filling and bleeding appliance
or
VAG1869 brake filling and bleeding appliance

WARNING!

Brake fluid is poisonous.
It must NEVER be removed by siphoning
with your mouth.
If brake fluid contacts skin or eyes, flush or
wash adequately to prevent irritation. Get
medical attention immediately if necessary.
Brake fluid must be disposed of properly.
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30-18

CAUTION!

Use only fresh brake fluid conforming to US
standard FMVSS 116 DOT 4. Genuine
VW/Audi brake fluid conforms to this
specification.
Brake fluid must never be brought into
contact with liquids containing mineral oil
(gasoline, cleaning agents). Mineral oil
damages the pistons and cups in the braking
system.
Brake fluid must not be allowed to come into
contact with paintwork because of its caustic
effect.
Brake fluid is hygroscopic (i.e. it absorbs
moisture from the surrounding air) and
should therefore always be kept in airtight
containers.
When carrying out the following steps, make
sure that no brake fluid escapes onto the
transmission.

Notes:
The clutch system must be bled after carrying
out work on the hydraulic clutch mechanism.
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Top-off brake fluid reservoir to "max." marking
with brake fluid before bleeding clutch system.

- Pull clutch pedal back to rest position.

- Connect VAG1238B brake filling and bleeding
appliance or VAG1869 but do not switch on.

- If necessary, remove noise insulation panel
under transmission.
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30-19


CAUTION!
Always comply with disposal regulations.
Note:
While bleeding, make sure bleeder hose remains correctly routed. - Connect bleeder hose -A- to clutch slave cylinder (arrow) and open
bleeder valve.
- Connect bleeder hose with pressure hose to collector bottle.
- Switch on bleeding appliance and let approx. 100 cm3 (approx. 3.4 fl.
oz) brake fluid flow into suitable collection reservoir.
Work pressure 2.5 bar (36 psi)
- Close bleeder valve.
Tightening torque: 4.5 Nm (40 in. lb).
- Depress clutch pedal several times after completion of bleeding
process.
- Bleed system again if necessary.
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