Master cylinder, removing and installing: Installing

Installation is perform in reverse sequence. Note the following:

Fig 1: Identifying Retaining Clip, Clutch Pedal, Bolts And Master Cylinder

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• Install master cylinder - 4  - and tighten bolts - 3  - to 20Nm.

Fig 2: Pushing Clutch Pedal To Lock Into Place, While Making Sure Mount Is Properly Secured In Clutch Pedal

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• Insert retaining clip - 1  - in clutch pedal.
• Lock clutch pedal in position by pressing in direction of - arrow  -. Make sure retaining clip - 1  - engages correctly in clutch pedal.

Fig 3: Location Of Clutch Pedal Switch F36 And Pedal Assembly Securing Bolt

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A second technician is required for the next step.

• Insert entire pedal cluster and tighten bolt - 1  - by hand. The second technician should guide hose/line assembly into master cylinder from plenum chamber.

Fig 4: Location Of Brake Servo Securing Bolts

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• Tighten bolts for brake servo - arrows  - to 25 Nm.

Fig 5: Installing Rubber Grommet And After-Run Hose

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• Press in retaining clip - C  - as far as it will go.
• Insert hose/line assembly - B  - in master cylinder and make sure that it engages audibly.
• Install rubber grommet - D  - onto connecting line for supply hose - A  - at bulkhead.
• Push supply hose - A  - from brake fluid reservoir on as far as it will go.

• Remove hose clamps 3094.

Fig 6: Location Of Brake Fluid Reservoir Dowel Bolt

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• Tighten securing bolt - 1  - for brake fluid reservoir and connect connector at brake fluid level warning contact.

Fig 7: Locating Steering Column At Steering Gear And Disconnecting Connector On Clutch Pedal Switch, Brake Pedal Switch And On Accelerator Pedal Module

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• Tighten hex socket head bolt - arrow B  - for securing pedal cluster to instrument panel carrier to 25Nm.
• Connect connectors - 1  - , - 2  - and - 3  -.
• If installed, plug in connector for clutch pedal switch F194.
• Connect brake pedal to brake servo → 47 - BRAKES - HYDRAULIC COMPONENTS .

• Secure steering column to steering gear - arrow A  - → 48 - STEERING .
• Install over-center spring.
• Install storage compartment on drivers side →
  • 68 - INTERIOR EQUIPMENT
  • 68 - INTERIOR EQUIPMENT for Cabriolet
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• Bleed clutch system → Clutch hydraulic system, bleeding .

Fig 8: Electronics Box Nuts

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• Insert electronics box and tighten nuts - arrows  - to 4Nm.
• Route engine wiring harness and connect connector in console.
• Install engine control module→
  • 28 - IGNITION/GLOW PLUG SYSTEM for AVK
  • 28 - IGNITION/GLOW PLUG SYSTEM for BPG
• If applicable, install auxiliary relay carrier and auxiliary fuse carrier →
  • 97 WIRING
  • 97 WIRING for Cabriolet
  .

• Press on cover (hand-tight) and tighten bolts in diagonal sequence to 4Nm.
• Follow steps required after connecting battery →
  • 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
  • 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for Cabriolet
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