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Driving a Volkswagen car with a manual transmission can be fun, and it gives you more control over the car. You can use the clutch to decelerate, lower the torque to the wheels, accelerate at higher rpm and even kill the engine. The whole system hinges on a clutch, which you use to change gears in the transmission and keep them from grinding each other during the speeding up and slowing down process of driving. If the clutch begins to feel less responsive or has too much slack, you may need to adjust it. Locate the clutch cable adjuster in the engine compartment. The cable adjuster, which consists of a white plastic adjuster and steel locknut, is on top of the transaxle on the left or driver's side of the engine compartment. Look for the white plastic locknut atop the transaxle just to the left of the battery as you are looking from the front of the vehicle. The clutch cable leads from the clutch cable adjuster through the firewall to the clutch cable.
Turn off the engine and set the parking brake. Depress the clutch pedal with your hand and feel how much free play or easy movement it has before you feel clutch resistance. The free play is the first easy movement in the pedal and you can test it by pushing the pedal with your finger. In contrast, you will probably need to use your whole hand to disengage the clutch and push the pedal the rest of the way to the floor. Measure the free play distance in the clutch pedal by holding the ruler at a right angle to the movement of the pedal. The specification for free play in the Golf clutch is 5/8 inch or 15mm. If the free play is greater than this it requires adjustment. Push the clutch pedal in and release it several times before making adjustments. Loosen the clutch cable locknut with a wrench.
Tighten the cable adjuster with your fingers until there is the specified amount of clutch free play. In 1985 and later models, insert the 15/32-inch spacer between the plastic flange of the adjuster and the transaxle housing beneath it. Turn the adjuster counterclockwise until the flange is snug on the spacer, and then tighten the locknut. Test the free play again to ensure it is still correct and make adjustments as necessary. Check the level of the clutch fluid in the reservoir in the VW Passat if the clutch isn't responding as it should. Fill the reservoir, which is located in the rear left of the engine bay, and pump the clutch pedal a few times to restore the pressure in the lines. If the level doesn't stay the same, this could be a sign of a leak in the system, either in the reservoir itself or the lines, or master or slave cylinders. Replace or repair any leaking parts. Replace the "stop clip" at the top of the clutch pedal in the VW Passat should you notice that the clutch pedal sits higher than the brake pedal.
