460519 Removing and installing brake pedal
WM 460519 Removing and installing brake pedal
Technical values
Information
The brake pedal can only be removed when the clutch pedal has been removed.
The description (removing and installing brake pedal) also covers the procedure for removing and installing the clutch pedal.
Overview of brake pedal
Preliminary work
1. Remove cover for centre console (driver's side) -> 681419 Removing and installing cover for centre console 681419 Removing and installing centre console cover.
2. Remove trim panel (lower part of dashboard)-> 701919 Removing and installing trim panel under dashboard 701919 Removing and Installing Trim Under Dashboard.
3. Remove Kessy control unit -> 96661900 Removing and installing KESSY/PAS control unit Service and Repair.
Removing clutch pedal
1. Remove lid and side trim panel on fuse box.
Installation position: In driver's footwell at the left.
2. Carefully pull off the connector from the clutch pedal switch (and interlock switch if necessary), see -Arrows-.
Clutch pedal switch
3. Remove device support.
The device support is installed at the left next to the clutch pedal together with the vehicle electrical system control unit and relay carrier.
3.1. Remove relay carrier.
3.2. Remove vehicle electrical system control unit.
3.3. Remove device support.
4. Secure clutch power spring.
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).
Secure clutch power spring using a cotter pin, for example. Press the clutch pedal lightly, then unclip and remove the clutch power spring.
5. Remove clutch master cylinder -Arrows- and pin (master cylinder valve pushrod) - do not open the clutch system.
Clutch master cylinder
6. Remove 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.
(Also remove clutch pedal switch and interlock switch, if necessary) => Bracket for clutch power spring. Carefully move bracket for clutch power spring approximately 2-4 mm to the left -A-. Carefully turn bracket for clutch power spring clockwise by approximately 10-15 degrees on the pedal bearing axle -B-. Remove bracket for clutch power spring to the left.
Bracket for clutch power spring
Removing brake pedal
Overview of brake pedal
1. Remove brake light switch.
Release brake light switch -1- by turning it 90° and pull it out of the installation opening.
2. Disconnect brake pushrod from brake pedal.
Brake pedal
Remove bolt and threaded bushing, see -Inset-.
3. Remove pedal axle.
Pedal axle
Screw out and remove lock nut -1b- and nut -1a- as well as pedal axle -2-.
4. Pull out brake pedal.
Brake pedal
Turn the brake pedal and brake pushrod as required, see -Inset-.
Installing brake pedal
Overview of brake pedal
1. Grease bracket for brake pedal.
Grease bracket close to the pedal bearing axle -Arrows- with Renocal (Glissando VW 745). Part No. 000.043.206.21 (10g tube).
2. Insert brake pedal.
Turn the brake pedal -7- and brake pushrod -6- as required.
3. Fit brake pushrod on brake pedal. Use a new bolt, see -Inset- (replace bolt after loosening).
Brake pedal
Tighten new bolt, see -Inset-.
=> Tightening torque: +10 Nm (+7.5 ftlb.)
4. Install pedal axle.
Tighten pedal axle -2-.
=> Tightening torque: +10 Nm (+7.5 ftlb.)-2 Nm (-1.5 ftlb.)
Installing clutch pedal
Information
Grease bracket in area of pedal bearing axle -arrows- with Renocal (Glissando VW 745). Part No. 000.043.206.21 (10g tube).
Advanced grease specification
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-.
Check bearings on the clutch power spring/clutch pedal (bushes, bearing shells) and the connection pieces for signs of wear. Replace any parts that are worn. Use new lock for pin.
Observe correct tightening torques.
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.
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.
Clutch master cylinder (push rod)
1. Insert bracket for clutch power spring with clutch pedal.
2. Install support for clutch pedal switch.
Support for clutch pedal switch
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.
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.
4. Fit the clutch master cylinder.
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!).
5. Check adjustment for clutch pedal switch (and interlock switch, if necessary).
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.
=> Adjustment for clutch pedal switch (interlock switch) Plug in connector.
Adjustment for clutch pedal switch (interlock switch)
6. Install device support.
The device support is installed at the left next to the clutch pedal together with the vehicle electrical system control unit and relay carrier.
6.1. Install device support.
6.2. Install vehicle electrical system control unit.
6.3. Install relay carrier.
7. Install side trim panel, fuse box and lid.
In driver's footwell at the left.
Subsequent work
1. Install Kessy control unit -> 966619 Removing and installing KESSY control unit Service and Repair.
2. Install trim panel (lower part of dashboard). -> 701919 Removing and installing trim panel under dashboard 701919 Removing and Installing Trim Under Dashboard.
3. Install covers for centre console -> 681419 Removing and installing centre console cover 681419 Removing and installing centre console cover.