21 52 500 Removing and installing/replacing clutch master cylinder

WARNING: This page is about a different variant/trim than selected.

NOTE: After completing work, bleed CLUTCH HYDRAULIC SYSTEM .

Necessary preliminary tasks:

Remove TRIM PANEL for pedal assembly.
Remove FOOTWELL MODULE .

Draw off brake fluid up to supply hose of clutch hydraulic system (1). For this purpose, use only a vacuum pipe that is exclusively used for removing brake fluid.

Detach supply hose (1) from expansion tank.

NOTE: Illustration similar.

Fig 1: Identifying Expansion Tank Supply Hose

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Release screws (1) on cylinder (2).

Tightening torque: 21 52 4AZ

Fig 2: Identifying Clutch Master Cylinder And Screws

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NOTE: Two versions of clutch pedal.

Version 1 - plastic clutch pedal

Disconnect return spring (1).

Detach locking clip (3) and pull clutch pedal with clutch master cylinder off bearing block.

Press pin ends (2) together and remove pin.

Fig 3: Identifying Return Spring And Retaining Clips

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Version 2 - metal clutch pedal

Detach retaining clip and remove clutch master cylinder from pedal

Installation:

Replace locking clip.

The locking clip must be seated with both legs in the pin groove.

Detach retainer (1) with a screwdriver (2).

NOTE: Do not foul carpet with brake fluid.

Detach hydraulic line from clutch master cylinder.

Fig 4: Detaching Retainer With Screwdriver

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Detach supply hose (1) from clutch master cylinder.

IMPORTANT: Do not pull supply hose completely into interior.

Fig 5: Identifying Clutch Master Cylinder Supply Hose

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Lever out shift element (1) from clutch master cylinder (2) with screwdriver.

Release plug connection (3) and disconnect plug (4) from shift element (1).

Fig 6: Disconnecting Plug From Shift Element

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Installation:

Shift element is secured against incorrect installation.

Shift element must snap audibly into place.

Fig 7: Identifying Clutch Switch

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