Hydraulic System, Assembly Overview

Hydraulic system, assembly overview, 02X, 6 Spd. M/T AWD





1 - Brake fluid reservoir
2 - Supply hose
^ For clutch master cylinder

3 - Line/hose assembly
^ For connections on master cylinder and slave cylinder
^ Disconnecting from master cylinder and installing
^ Disconnecting from slave cylinder
^ Refer to Parts catalog for correct version for LHD and RHD vehicles

4 - Grommet
5 - Mounting bracket
6 - Clutch pedal
7 - Master cylinder
^ Removing and installing
^ Do not remove clip - arrowA - or seal - arrowB -.
^ To remove line/hose assembly, pull out clip - arrowA -, but only as far as limit stop.

8 - Hex socket head bolt, 20 Nm
9 - Retaining clip
^ Only replace when master cylinder has been removed
^ Pry off to remove
^ Push in to install

10 - Transmission
11 - Slave cylinder
^ Do not operate clutch pedal after slave cylinder has been removed.
^ Removing and installing
^ Bleed slave cylinder after working on hydraulic clutch mechanism
^ Disconnecting hose/line assembly
^ Do not allow brake fluid to come into contact with transmission.

12 - Bleeder valve
^ Tighten to 4.5 Nm
^ Follow correct procedure when bleeding
^ If bleeder valve has broken off, it can be removed with 3 mm Allen key

13 - Dust cap
14 - Clip
^ To remove line pull out clip as far as limit stop

15 - Bracket
^ For line/hose assembly
^ Attached to transmission together with slave cylinder

16 - Hex socket head bolt, 25 Nm
^ Slave cylinder to transmission
^ Self-locking
^ Replace

17 - Retaining clip
18 - Gasket
19 - Securing bolt
^ For brake fluid reservoir





Prying retaining clip - A - off in direction of - arrow -





Pressing master cylinder operating rod into retaining clip - A - (in direction of - arrow -).





Disconnecting slave cylinder from hose/line assembly
Removing
- To remove hose/line assembly, use a screwdriver to pry off clip - A - as far as stop. Only then can the hose/line assembly be pulled out.

Installing
- Press retaining clip - A - in as far as it will go.
- Insert hose/line assembly in slave cylinder and make sure that it engages audibly.
- Pull on line/hose assembly to check it is secure.