GENERAL INFORMATION

Keep dirt out of open pipe/hose connections (e.g. install caps). Brake fluid will
damage sheet metal and paint finishes. Rinse off coated surfaces with a generous
amount of water.
Always replace self-locking nuts.
Always stop operation of doors (automatic cutout/danger of injury) for all jobs
on the pedals.

Approved Lubricating Grease:
Renocal -- FN 745
Glissando -- VW 745
 
Accelerator Cable Adjusting Procedures
for Manual Transmission Cars

1. Accelerator pedal in neutral position
(accelerator pedal on idle stop).
2. Throttle valve in neutral position
(automatic choke switched off).
3. Adjust cable without tension.
4. Adjust adjusting screw on full
throttle stop of pedal console in
such a manner, that there is still
0.5 mm (0.020") clearance on the
throttle valve of an injection engine
with the accelerator pedal on the
full throttle stop in full throttle
position.
Loosening the adjusting screw one
and one half turns is equal to a
clearance of 0.5 mm (0.020").
 
Adjusting Push Rod of Brake Pedal:

Adjust brake pedal to distance A =
243 + 5 mm (9.567 + 0.197") on brake
master cylinder push rod (1).
Adjust stop light switch - see Gr. 61.
Check function of stop lights!


Siehe auch 61 31 000
135001 - click to zoom
 
Adjusting Eccentric Bolt of Clutch
Pedal:

Turn eccentric bolt until doe on exxentric
bolt is opposite the clutch master
cylinder.

135002 - click to zoom
 
Distance B = 231 + 10 mm (9.094 +
0.304") must now be reached.
If distance B is not reached with the
previously described adjustment, turn
the eccentric bolt 180°.

Important!
Intermediate positioning of the eccentric
bolt is not approved!

3235035 - click to zoom
 
Bleed clutch.

Before after After Bleeding:
Check / correct level of hydraulic fluid
in the tank.
 
Clutch Bleeding Procedures:

1. Connect bleeder.
2. Loosen bleeder screw on slave
cylinder.
3. Bleed at least 30 seconds.
4. Tighten bleeder screw.
5. Install cap.
6. Remove bleeder.

Bleed with a pressure of 3 + 1 bar
(43 + 14 psi).
 
Note:
If there is still air in the hydarulic system
after bleeding several times, the
slave cylinder must be unscrewed on
the transmission. Press push rod
against the stop in the slave cylinder
and release it slowly. This will force
any residual air back into the supply
tank and provide maximum release
travel.
Never operate the clutch pedal as long
as the slave cylinder is removed.