PRE-RELEASE
Master cylinder (LHD)
| Master cylinder (LHD) |
| To remove |
| 1. |
Remove the lower section of the dashboard beneath the steering wheel (data link connector and floor lighting). Refer to
Dashboard.
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| 2. |
Lift the spring from the clutch pedal.
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| 3. |
Remove the clip and pin from the clutch pedal.
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| 4. |
Place a cover over the splash guard to protect it from any brake fluid spillage.
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| 5. |
Remove the battery cover and the battery.
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| 6. |
(V6 diesel) Remove the turbocharger heat shield.
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| 7. |
Disconnect the electrical distribution unit and move it aside.
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| 8. |
Empty the clutch system by connecting
88 19 096 Bleeding equipment
. Draw out the brake fluid through the bleed nipple.
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| 9. |
Disconnect the supply hose from the brake fluid reservoir.
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| 10. |
Disconnect the connector from the ABS unit and place it to one side.
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| 11. |
Clean around the brake pipe connections using compressed air.
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| 12. |
Disconnect the brake pipes and plug the holes.
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| 13. |
Remove the ABS unit.
It may be necessary to insert a screwdriver between the bracket and the wheel housing and prise carefully in order to reach the nut. |
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| 14. |
Remove the ABS unit bracket.
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| 15. |
Undo the clip securing the delivery pipe to the master cylinder.
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| 16. |
Detach the delivery pipe from the master cylinder.
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| 17. |
Remove the nuts securing the master cylinder.
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| 18. |
Remove the master cylinder.
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| 19. |
Move the hose to the new master cylinder.
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| To fit |
| 1. |
Fit the clip to the master cylinder.
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| 2. |
Fit the master cylinder and tighten the nuts.
Tightening torque 20 Nm (15 lbf ft ) 
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| 3. |
Connect the delivery pipe. Press the pipe into the plastic clip.
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| 4. |
Fit the pin and clip to the clutch pedal.
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| 5. |
Hook the spring onto the clutch pedal.
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| 6. |
Depress the pedal and pull out the push rod in the switch. Pull up the pedal again so that the switch is adjusted to the correct position.
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| 7. |
Fit the lower section of the dashboard, refer to
Dashboard
, data link connector and floor lighting.
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| 8. |
Connect the supply hose to the reservoir.
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| 9. |
Fit the ABS unit bracket.
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| 10. |
Fit the ABS unit and plug in the connector.
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| 11. |
Remove the plugs and connect the brake pipes.
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| 12. |
Connect the supply hose to the brake fluid reservoir. Fit the hose clip upwards.
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| 13. |
Fill the system with brake fluid and bleed as described under
Bleeding the clutch hydraulic system in the car
.
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| 14. |
Bleed the brake system, see
Bleeding the brake system.
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| 15. |
Fit the electrical distribution unit.
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| 16. |
V6 diesel
: Fit the turbocharger heat shield.
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| 17. |
Fit the battery and battery cover.
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| 18. |
Test the clutch and brakes.
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| 19. |
Remove the splash guard cover.
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| 20. |
Set the car's clock.
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