Clutch Hydraulic System: Service and Repair

Hydraulic system, general layout
1. Brake fluid reservoir
2. Supply hose
3. Line/hose assembly
^ For plug-in connections on master cylinder and slave cylinder
^ Disconnecting from master cylinder and installing, Refer to Clutch Master Cylinder, Service and Repair
^ Disconnecting from slave cylinder, Refer to Fig. 2
^ Allocation
Refer to Parts Supplier
4. Mounting bracket
5. Clutch pedal
^ Removing and installing, Refer to Clutch Pedal Assembly, Service and Repair.
6. Hex socket head bolt, 20 Nm
7. Pin
8. Master cylinder
^ With plug-in connection for hose/line assembly
^ Removing and installing, Refer to Clutch Master Cylinder, Service and Repair
9. Seal
^ Must not be removed
10. Retaining clip
^ Pull out retaining clip to disconnect line, Refer to Clutch Master Cylinder, Service and Repair
11. Transmission
12. Plastic slave cylinder
^ Do not operate clutch pedal after slave cylinder has been removed
^ Brake fluid must not be allowed to get onto the transmission
^ Lightly grease to install, Refer to Fig. 1
^ When installing push in until the securing bolt can be fitted.
^ With plug in connection for hose/line assembly
^ Disconnecting hose/line assembly, Refer to Fig. 2
^ Follow correct sequence of work when bleeding, Refer to Clutch, M/T, Service and Repair
13. Bleeder valve
^ Tighten to 4.5 Nm
^ Follow correct sequence of work when bleeding, Refer to Clutch, M/T, Service and Repair
^ A broken off bleeder valve can be removed using a 3mm hex socket wrench
14. Dust cap
15. Retaining clip
^ Pull out retaining clip to disconnect line, Refer to Fig. 2
16. Bracket
^ Secured to transmission
17. Hex socket head bolt
^ 20 Nm
18. Nut
^ 2 Nm
19. Seal





Fig. 1 Installing clutch slave cylinder
- Coat area -a- of collar with lithium grease G 052 150 A2 before installing slave cylinder into transmission housing.
- Lightly coat contact surface for plunger to clutch release lever with copper grease, e.g. Z 381 351 TE.





Fig. 2 Disconnecting line and clutch slave cylinder

Removing
- To disconnect line, use a screwdriver to pry out retaining clip -A- so that it clicks. Line can then be pulled out.

Installing
- Press in retaining clip -A- as far as it will go.
- Push line into slave cylinder until it engages audibly.