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Master Cylinder - LHD: Installation

WARNING: This page is about a different car, the 2006 Chrysler PT Cruiser. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Clutch Master Cylinder
GC0022829Courtesy of DAIMLERCHRYSLER CORP.
1 - CLUTCH MASTER CYLINDER
  1. Install clutch master cylinder (1) into position See Fig 1.but do not fasten to dash panel at this time.  . Carefully route hydraulic pipe into position as removed.
    Fig 2: Hydraulic Tube Retaining Clips
    GC0022806Courtesy of DAIMLERCHRYSLER CORP.
    1 - RETAINER CLIPS
  2. Connect hydraulic supply tube to clutch slave cylinder:
    • 1.6L/2.4L N/A Models:  Raise vehicle on hoist, depress both retaining clips to secure and Insert tube into slave cylinder port (1) and verify connection by pulling outward. Lower vehicle. See Fig 2.
    • 2.4L Turbo & 2.2L Diesel Models:  depress both retaining clips to secure, Insert tube into slave cylinder port and verify connection by pulling outward.
    Fig 3: Clutch Master Cylinder Supply Hose
    GC0022832Courtesy of DAIMLERCHRYSLER CORP.
    1 - BRAKE MASTER CYLINDER RESERVOIR
    2 - HOSE CLAMP
    3 - CLUTCH MASTER CYLINDER SUPPLY HOSE
  3. Connect clutch master cylinder supply hose to brake master cylinder reservoir (1) and secure with clamp. See Fig 3.
    Fig 4: Opening Hydraulic Circuit Bleed - 1.6/2.4L Models
    GC0022802Courtesy of DAIMLERCHRYSLER CORP.
    1 - RETAINING RING
    2 - CLEAR HOSE
    3 - HYDRAULIC TUBE
    Fig 5: Opening Hydraulic Circuit Bleed Port
    GC0022801Courtesy of DAIMLERCHRYSLER CORP.
    1 - CLEAR HOSE
    2 - HYDRAULIC TUBE
    3 - INNER RETAINER RING
  4. Fill clutch hydraulic release system with fluid:
    • 1.6L/2.4L N/A Models:  Fill brake master cylinder to the top with suitable DOT3 fluid. Leave cap off. Raise vehicle on hoist.
    • Remove bleed port protective cap, and install suitable size and length of clear hose (2) to monitor and divert fluid into suitable container. See Fig 4.
    • Release only the lower hydraulic tube snap ring (1), pull outward on tube (3) until it stops against the second ring, opening up the bleed circuit and starting the air purge and fluid fill process.
    • Lower vehicle, but only enough to gain access to and fill the brake master cylinder.
    • Top off brake master cylinder fluid level while air is purged and fluid drains from bleed port. Continue this until no air bubbles are seen and a solid column of fluid exists.
    • Rapidly depress and release clutch peddle 10 times while purging. Insure the reservoir maintains fluid and the drain hose at the bleed port stays submerged in fluid in a collection container.
    • Close hydraulic bleed circuit. Insert hydraulic pipe fully into slave cylinder and depress retaining ring. Remove drain hose. Replace dust cap on bleed port.
    • 2.4L Turbo & 2.2L Turbo Diesel  Fill brake master cylinder to the top with suitable DOT3 fluid. Leave cap off.
    • Remove bleed port protective cap, and install suitable size and length of clear hose (1) to divert fluid into suitable container. See Fig 5.
    • Release only the inboard hydraulic tube snap ring (3), pull outward on tube (2) until it stops against the second ring, opening up the bleed circuit and starting the fluid fill process.
    • Rapidly depress and release clutch peddle 10 times while purging. Insure the reservoir maintains fluid and the drain hose at the bleed port stays submerged in fluid in a collection container.
    • Top off brake master cylinder fluid level while air is purged and fluid drains from bleed port. Continue this until no air bubbles are seen and a solid column of fluid exists.
    • Close hydraulic bleed circuit. Insert hydraulic pipe fully into slave cylinder and depress retaining ring. Remove drain hose. Replace dust cap on bleed port.
    Fig 6: Master Cylinder Mounting Nuts
    GC0019804Courtesy of DAIMLERCHRYSLER CORP.
    1 - MASTER CYLINDER
    2 - NUTS
    CAUTION: Due to clutch master cylinder design and placement, the master cylinder body traps a significant amount of air which does not purge by means of normal methods. It is necessary to position master cylinder body vertical, with pushrod pointing down, for about ten seconds to purge air trapped from end of cylinder. Failure to perform this step upon assembly will result in inadequate system bleeding and poor release system functionality.
  5. Verify that brake master cylinder reservoir is full and cap is off.
  6. Position clutch master cylinder body vertically, with pushrod pointing down, for about ten seconds to purge air trapped from end of cylinder.
  7. Install clutch master cylinder body to dash panel. From inside vehicle, install and torque two clutch master cylinder-to-dash panel retaining nuts (2) to 15 N.m (130 in. lbs.) torque. See Fig 6.
    Fig 7: Locating Clutch Master Cylinder Pushrod Adjustment Screw
    GC0022826Courtesy of DAIMLERCHRYSLER CORP.
    1 - ADJUSTMENT SCREW
  8. Loosen master cylinder pushrod adjustment screw (1). See Fig 7.
  9. Connect clutch master cylinder rod to clutch pedal pin. An audible "click" should be heard. If damaged, replace nylon retainer.
  10. Adjust clutch pedal position. Gently lift upward on clutch pedal. Tighten adjustment screw to 6 N.m (55 in. lbs.) torque.
    Fig 8: Brake Booster Mounting Nuts
    GC0019805Courtesy of DAIMLERCHRYSLER CORP.
    1 - CLIP
    2 - BOOSTER MOUNTING NUTS
    3 - BOOSTER MOUNTING NUTS
  11. Install brake booster into position. Connect push rod to brake pedal pin (1). See Fig 8.
  12. Install and torque brake booster-to-cowl panel nuts (2) to 34 N.m (300 in.lbs.). Install push rod retaining clip (1).
    Fig 9: Lower Instrument Panel Bezel
    G04241533Courtesy of DAIMLERCHRYSLER CORP.
  13. Replace stop lamp switch. Refer to Stop Lamp Switch Removal and Installation under PEDAL .
  14. Install lower instrument panel bezel (2). See Fig 9.
    Fig 10: Air Cleaner Assembly Removal/Installation - Typical
    GC0022831Courtesy of DAIMLERCHRYSLER CORP.
    1 - AIR CLEANER ASSEMBLY
  15. Install PDC bracket into position.
  16. Connect battery negative cable.
  17. Install air cleaner assembly (1). See Fig 10.
  18. Verify that brake master cylinder reservoir is full. Top off with DOT 3 brake fluid if necessary.
  19. Actuate clutch pedal a minimum of fifty times to allow any air ingested into the system to vent to the master cylinder reservoir. If residual air becomes trapped in the system, it is necessary to bleed the clutch hydraulic system. (Refer to CLUTCH - STANDARD PROCEDURE) .
  20. Verify proper clutch release system operation.
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