2. From within the car remove the bottom panel from under a steering column.
3. Remove the bracket and remove the pin securing the master cylinder push rod to the clutch pedal.
4. In the engine compartment, disconnect and plug the feed pipe from the master cylinder.
5. Unscrew and disconnect the discharge pipe (photo). Plug the line to prevent dust and dirt from entering.
6. Remove the sealing ring from the baffle.
7. Turn off mounting bolts from within the car, then get the main cylinder from the inside of a motor compartment.
8. Repair kits are not manufactured by Audi, but can be purchased from your vehicle and parts dealer.
9. Before overhauling the master cylinder, first clean the outer surfaces.
10. Remove a rubber boot remove a pusher bar. If necessary, loosen the lock nut, unscrew the clamp and lock nut, remove the push rod from the rubber boot.
11. Remove the retaining ring from the cylinder bell, remove the washer, piston and spring, noting that the smaller end of the spring touches the piston.
12. Clean the parts with methanol, check their condition. If the piston and bore are excessively worn, replace the cylinder, but if they are in good condition, remove the seals from the piston and prepare new ones.
13. Dip new seals in hydraulic fluid, install on piston. Make sure the seal lip faces towards the end of the piston spring.
14. Insert the large end of the spring into the cylinder. Dip the piston in the hydraulic fluid, place it on the spring and carefully insert.
15. Install the washer, then position the circlip in the groove.
16. Apply savory to the end of the push rod, then place it on the piston, install the rubber boot. Screw on the locknut and clamp, tighten the locknut.
17. Installation is carried out in the reverse order. Bleed the hydraulic system as described in Chapter 4.
18. Lubricate the pin.
19. Check that the clutch pedal in its original position is approximately 10 mm higher than the brake pedal. If necessary, adjust the position of the pedal by loosening the lock nut, turning the push rod as required, and tightening the lock nut again.
20. Check that the distance between the center of the pin and the baffle is 116.0±0.2mm (Pic. 5.3).
21. Check that the spring returns the pedal correctly and that the pedal does not touch the suspension in its original position. A pedal return failure may be due to air in the hydraulic system or a seized pedal bearing.
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