Special Tools Audi A4 B6

Special Tools

For special tools for clutch master cylinder work (Scheme 181)and (Scheme 182).

Scheme 180

Scheme 181

Scheme 182

Scheme 183

Scheme 184

Scheme 185

Scheme 186

Scheme 187

Scheme 188

Scheme 189

Scheme 190

Scheme 191

Scheme 192

Scheme 193

Scheme 194

Scheme 195

Scheme 196

1. Remove rubber seal from plenum chamber in direction of arrow. (Scheme 183) Remove cover (1) over plenum chamber.
2. Disconnect battery ground strap with ignition switched off.
3. Use screwdriver to pry off the two caps (3). (Scheme 184) Remove nuts (4) and detach the two wiper arms (2). Pull off clips (1) and remove cowl panel grille (5).
4. Remove electronics box in plenum chamber as follows: Screw out bolts (arrows) and pull off sealing cover. (Scheme 185) Carefully pry off retainer bar with screwdriver (arrow). (Scheme 186) Release connector latches (arrows) and pull off connectors (1) and (2) on engine control module. (Scheme 187) Pull off connector (2) from connector rail. (Scheme 188) Disconnect wire (1). (Scheme 188) Release catches (arrows) and pull auxiliary relay carrier in electronics box upward to remove. (Scheme 189) Pull engine wiring harness together with rubber grommet out of recess in electronics box. Remove nuts (arrows) and lift out electronics box (1). (Scheme 190)
5. Clamp supply hose (A) leading to brake fluid reservoir using special tool 3094. Pull hose off at master cylinder and plug it. (Scheme 191)
6. Disconnect supply hose (A) to brake fluid reservoir with special tool 3094, detach from master cylinder and seal with plug. On bulkhead remove grommet above connecting tube for supply hose. Use a screwdriver to pry out retaining clip (C) and then pull out line (B) slightly. (Scheme 191)
7. Remove bolt from brake fluid reservoir (1) and disconnect connector from fluid level below. (Scheme 192)
8. To remove the top Torx(R) bolt, swivel brake fluid reservoir slightly to one side. Remove the two Torx(R) bolts (arrows). (Scheme 193) Remove vacuum line from brake servo (1).
9. Remove driver's side storage compartment. (Scheme 194)
10. Disconnect brake light switch harness connector. (Scheme 195)
11. Separate brake pedal from brake servo using release tool T40024. (Scheme 196)
12. Disconnect steering column from steering gear (arrow A). (Scheme 197)
13. Disconnect connector on clutch pedal switch (1), brake pedal switch (2) and on accelerator pedal module (3). (Scheme 197)
14. Remove securing bolt from mounting bracket (arrow B) and complete pedal cluster. (Scheme 197)
15. Removing over-center spring. See «CLUTCH PEDAL & OVERCENTER SPRING»(/audi/a4/b6-2000-2006/remont/clutches-manual-hydraulic/#clutches-01a-awd__clutch-pedal-overcenter-spring).
16. Insert pliers VAG 1922 into recess of clutch pedal, press retainer together (arrows) and detach clutch pedal from master cylinder. (Scheme 198)
17. Remove retaining clip (1) and pull off clutch pedal (2). (Scheme 199) Remove bolts (3) and detach master cylinder (4).
18. Pull off retainer (A) in direction of arrow. (Scheme 200)

Scheme 197

Scheme 198

Scheme 199

Scheme 200

Scheme 201

1. Press master cylinder operating rod into retainer (A) in direction of arrow. (Scheme 201)
2. Insert master cylinder and tighten screws (3) to 15 ft. lbs. (20 N.). (Scheme 199)
3. Insert retainer into clutch pedal. See No. 10 in (Scheme 180). Press clutch pedal to engage master cylinder retainer. Make sure that retainer is correctly locked in clutch pedal.
4. Install over-center spring. See «CLUTCH PEDAL & OVERCENTER SPRING»(/audi/a4/b6-2000-2006/remont/clutches-manual-hydraulic/#clutches-01a-awd__clutch-pedal-overcenter-spring).
5. A second mechanic is required for this step. Insert complete pedal cluster and install bolt (1) hand-tight. (Scheme 202) The second mechanic must simultaneously insert line into master cylinder from plenum chamber side.
6. Tighten bolts for brake servo (arrows) to 18 ft. lbs. (25 N.m). (Scheme 203)
7. Press in retaining clip (C) up to stop. (Scheme 204) Insert line (B) into master cylinder until it is heard to engage. (Scheme 204) Insert rubber grommet (D) over supply hose connecting line (A) into bulkhead.
8. Slide supply hose (A) for the brake fluid reservoir up to stop. (Scheme 204) Remove special tool 3094. Install bolt for brake fluid reservoir.
9. Tighten hex socket-head bolt for securing pedal cluster on instrument panel support to 18 ft. lbs. (25 N.m).
10. Plug in harness connectors. Connect brake pedal to brake servo.
11. Secure steering column to steering gear. Tighten bolt to 22 ft. lbs. (30 N.m).
12. Install driver's storage compartment.
13. Bleed clutch system. See «CLUTCH HYDRAULIC SYSTEM»(/audi/a4/b6-2000-2006/remont/clutches-manual-hydraulic/#clutches-01a-awd__clutch-hydraulic-system) under BLEEDING.
14. Insert electronics box and tighten nuts (arrows) to 35 INCH lbs. (4 Nm). (Scheme 205) Route engine wiring harness and connect connectors to connector point. Install engine control module and if applicable auxiliary relay carrier with auxiliary fuse carrier.
15. Press on sealing cover hand-tight and tighten screws in diagonal sequence to 35 INCH lbs. (4 Nm). On re-connecting battery, remember to check and re-activate vehicle equipment (radio, clock, convenience electronics, etc.).

Scheme 202

1. Use a screwdriver to remove hose and line assembly, pull out clip (A) up to stop. (Scheme 206)
2. Separate slave cylinder from hose and pipe assembly. Pull out hose and pipe assembly. (Scheme 206).

Scheme 203

1. Push in clip (A) as far as it will go. (Scheme 206) Insert hose/pipe assembly in slave cylinder until it clicks into position. Check proper installation by pulling hose/pipe assembly.
2. Apply a thin layer of copper paste (e.g. Z 381 351 TE) to contact surface for plunger on clutch release lever. (Scheme 207) Before installing slave cylinder in transmission housing lubricate area (a) of boot with lithium base grease G 052 150 A2.
3. Lock bracket for hose/pipe assembly (3) on slave cylinder (4) and bolt onto transmission together with slave cylinder. (Scheme 208) Insert clutch slave cylinder into hole of transmission housing without major lateral deviation from direction of motion of plunger. (Scheme 208)
4. Bleed clutch system. See «CLUTCH HYDRAULIC SYSTEM»(/audi/a4/b6-2000-2006/remont/clutches-manual-hydraulic/#clutches-01a-awd__clutch-hydraulic-system) under BLEEDING.