Master Cylinder - LHD: Removal

Fig 1: Air Cleaner Assembly Removal/Installation - Typical

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1 - AIR CLEANER ASSEMBLY

Remove air cleaner assembly (1). See Fig 1.
Disconnect battery negative cable.

Fig 2: Lower Instrument Panel Bezel
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Remove lower instrument panel bezel (2). See Fig 2.

Fig 3: Brake Booster Mounting Nuts

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1 - CLIP

2 - BOOSTER MOUNTING NUTS

3 - BOOSTER MOUNTING NUTS

Remove clip and disconnect the brake booster input rod from the brake pedal pin (1). See Fig 3.
Remove the brake booster mounting nuts (2).
Slide brake booster forward enough to gain access to and remove clutch master cylinder.
Disconnect clutch master cylinder pushrod from clutch pedal. Inspect retainer bushing and replace if damaged in any way.

Fig 4: Master Cylinder Mounting Nuts
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1 - MASTER CYLINDER

2 - NUTS
Remove two clutch master cylinder retaining nuts (2). See Fig 4.
Remove PDC bracket and position out of way.

Fig 5: Hydraulic Tube Retainer Clips
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1 - RETAINER CLIPS

Disconnect hydraulic supply tube at clutch slave cylinder. To completely drain clutch master cylinder and tubing, remove brake master cylinder cap.

1.6L/2.4L N/A Models: Raise vehicle on hoist. Using suitable screwdriver, release both hydraulic tube retaining clips (1). See Fig 5. Disconnect tube and drain fluid into suitable container. Lower vehicle.

Fig 6: Hydraulic Tube Retainer Clips - Diesel/Turbo
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1 - RETAINER CLIPS
2.4L Turbo & Diesel Models: Using suitable screwdriver, release both hydraulic tube retaining clips (1). See Fig 6. Disconnect tube and drain fluid into suitable container.

Fig 7: Clutch Master Cylinder Supply Hose

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1 - BRAKE MASTER CYLINDER RESERVOIR

2 - HOSE CLAMP

3 - CLUTCH MASTER CYLINDER SUPPLY HOSE

Disconnect clutch master cylinder supply line from brake master cylinder reservoir (1). See Fig 7. Cap off or collect fluid spillage from reservoir port.
CAUTION: Use care when removing clutch master cylinder from engine compartment. Aggressive handling can result in a damaged hydraulic tube and improper clutch release operation upon reassembly.

CAUTION: Brake fluid will damage painted surfaces. If brake fluid is spilled on any painted surfaces, wash it off immediately with water.

Fig 8: Clutch Master Cylinder
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1 - CLUTCH MASTER CYLINDER
Remove master cylinder assembly (1) from mounting position and carefully work hydraulic pipe from out of left rail retainer and engine compartment. See Fig 8.