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Clutch Pedal Assembly: Service and Repair


Removing and installing the clutch pedal





Preliminary work

1. Removing trim panel (lower part of dashboard). To do this, remove the center console covers.





Side trim panels, left footwell (center console)

2. Unscrew the fastening screws -1- and swivel the trim panel under the dashboard on the drivers side -2- downwards -arrow A-.





Removing trim panel (lower part of dashboard)

General warning notes

Caution
Increased risk of accidents when removing/installing the clutch boost spring.
^ Possible risk of damage and injury (e.g. crushing).

-> The boost spring must be secured with a cotter pin when working near the clutch pedal (except for work on the clutch pedal switch and interlock switch).





Removing

1. Remove the cover and side trim panel for the fusebox in the left driver's footwell.
2. Carefully pull off the connector from the clutch pedal switch (and interlock switch if necessary) -Arrows-.





Clutch pedal switch

3. Remove the relay carrier, vehicle electrical system control unit, and device support on the left above the clutch pedal.
4. Secure clutch power spring with a cotter pin, for example. Press the clutch pedal lightly, unclip the clutch power spring and remove.
5. Loosen the clutch master cylinder -Arrows- (do not open the clutch system!) and remove the pin (master cylinder valve pushrod).





Clutch master cylinder

6. Loosen bracket for clutch power spring (support for clutch pedal switch and remove interlock switch, if necessary). Carefully move bracket for clutch power spring approximately 2-4 mm to the left -A-. Carefully turn bracket for clutch power spring clockwise on the pedal bearing axle approximately 10-15 degrees -B-.





Bracket for clutch power spring

Information
When removing the bracket for the clutch power spring, carefully guide the master cylinder valve pushrod past at the clutch pedal.

7. Pull out bracket for clutch power spring to the left and take out the clutch pedal.

Installing

Information





Advanced grease specification

Grease bracket in area of pedal bearing axle -Arrows- with Renocal (Glissando VW 745). Part No. 000.043.206.21 (10g tube).

Important: By contrast with previous models, do not grease the pedal bearing axle in the area of the clutch pedal -A- (due to plastic-coated bearing sleeves).

Also grease the following contact surfaces with Renocal (Glissando VW 745) (Part No. 000.043.206.21): The clutch pedal switch (interlock switch) system -Arrow-. In addition, the contact surface between the clutch pedal (inside of prongs) -Arrow- and the guiding rods of the clutch power spring -Arrow-.

Observe correct tightening torques.

Use new lock for bolts.

When installing the bracket for clutch power spring, insert the valve pushrod for the master cylinder carefully into the specified position in the clutch pedal.





Clutch master cylinder (push rod)

If creaking noises (over approx. 2/3 of the lift area) are heard after installing the clutch pedal, these may be coming from the connection between the ball head piston rod and piston seat of the clutch master cylinder -Arrow-. In this case, spray a minimal amount of multipurpose oil on the connection point using a metering tube -Arrow-. Important: The lubricant must only be applied to this connection point so make sure not to use too much. This connection point cannot be taken apart without damaging it irreparably.

1. Insert bracket for clutch power spring with clutch pedal.
2. Position support for clutch pedal switch (and interlock switch, if necessary) in the correct position.

Observe the auxiliary bar! -Arrow- The auxiliary bar must be fitted in the correct position in the groove.





Clutch pedal switch support

3. Install clutch power spring. Observe the installation position of the bolt for the clutch power spring (hexagon!). After installation, remove the clutch power spring cotter pin.

Information
Insert pin. Screw in the fastening screws slightly so that the master cylinder can still be moved. Have the clutch pedal not actuated at the limit stop. Press the clutch master cylinder in the direction of travel and tighten (make sure the return bore in the clutch master cylinder is not blocked!).

4. Mount the clutch master cylinder.

Information
If the clutch pedal switch adjustment (interlock switch) has been changed, the adjustment must be checked or adjusted. The switch must switch when the clutch pedal is actuated approx. 1-2 mm before the limit stop of the clutch master cylinder.

5. Check adjustment for clutch pedal switch (and interlock switch, if necessary). Plug in connector.





Adjustment for clutch pedal switch (interlock switch)

6. Install device support, vehicle electrical system control unit and relay carrier.
7. Install the side trim panel for the fusebox and cover in the left driver's footwell.

Subsequent work

1. Screw in the fastening screws -1- and swivel the trim panel under the dashboard on the driver's side -2- upwards -arrow A-.





Installing trim panel (lower part of dashboard)

2. Install covers for center console.
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