Removing and installing/replacing clutch master cylinder

Necessary preliminary work:

Remove TRIM PANEL for pedal assembly

Removal:

Turn locks (1) 90° counter-clockwise.

Lift clamp (2).

Remove cover (3).

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Draw off brake fluid up to supply hose (1) of clutch hydraulic system.

For this purpose, use only a vacuum pipe that is exclusively used for removing brake fluid.

Detach supply hose (1) from expansion tank.

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Detach retainers (1).

Slide out bolts (2).

Remove over-center helper spring.

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Release screws (1) on clutch master cylinder (2).

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Detach return spring (1).

Detach retaining clip (3) and pull clutch pedal with clutch master cylinder off bearing support.

Press bolt end (2) together and remove bolt.

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

IMPORTANT: Protect the carpet from contamination with brake fluid using suitable agents.

Detach hydraulic line from clutch master cylinder (3).

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Detach supply hose (1) from clutch master cylinder.

IMPORTANT: Do not pull supply hose completely into passenger compartment.

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Lever clutch switch (1) out of clutch master cylinder (2) with a screwdriver.

Release plug connection (3) and disconnect connector (4) from clutch switch (1).

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Installation:

Installation note:

The clutch switch is secured against incorrect assembly.

The clutch switch must snap audibly into place.

Engage connector (4) in plug connection (3).

Lock clutch switch (1) with clutch master cylinder (2).

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Plug supply hose (1) into connection on clutch master cylinder.

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Plug hydraulic line into clutch master cylinder (3) and secure with clamp (1).

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Press bolt ends (2) together and remove bolt.

Slide clutch pedal with clutch master cylinder onto bearing support and secure with retaining clip (3).

Attach return spring (1).

Part : Replace retaining clip and bolt.

The retaining clip must be seated with both shanks in the bolt groove.

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Tighten screws (1) on clutch master cylinder (2).

Tightening torque 21 52 2AZ .

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Install over-center helper spring.

Slide in bolts (2).

Engage retainers (1) audibly.

Part : Replace retaining clips and bolts.

Installation note:

Lightly grease bolts (2).

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Connect supply hose (1) to expansion tank.

Top up brake fluid up to supply hose (1) of clutch hydraulic system.

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Install cover (3).

Insert clamps (2).

Turn locks (1) 90° clockwise.

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NOTE: After completing repair work, bleed CLUTCH HYDRAULIC SYSTEM .

Required follow-up work:

Install TRIM PANEL for pedal mechanism