Removal and Replacement

Hydraulic System Assembly Overview





1 Brake fluid reservoir

2 Supply hose

• For clutch master cylinder

3 Hose/line assembly

• For connectors on clutch master/slave cylinder

• Disconnect from clutch master cylinder and install => [ Pry retaining clip out
with a screwdriver and then pull hose/line assembly out
a little. ] Service and Repair

• Disconnect from clutch slave cylinder, refer to => [ Disconnect clutch slave cylinder from hose/line assembly ]

4 Grommet

5 Mounting bracket

6 Clutch pedal

7 Clutch master cylinder

• Removing and installing, refer to => [ Clutch Master Cylinder ] Service and Repair

• Clip - arrow A - and seal - arrow B - must not be removed

• To remove the hose/line assembly clip - arrow A -, only pull out to the stop => [ Pry retaining clip out
with a screwdriver and then pull hose/line assembly out
a little. ] Service and Repair

8 Internal hex bolt - 20 Nm

9 Base block

• Only replace with clutch master cylinder removed

• Prying off, refer to => [ Pry off mount in direction
of ]

• Pressing in, refer to => [ Press master cylinder actuator rod into mounting (direction of ) ]

10 Transmission

11 Clutch slave cylinder

• Do not operate clutch pedal after removal

• Removing and installing, refer to => [ Clutch Slave Cylinder ] 02XA Transmission

• After working on hydraulic clutch mechanism, bleed clutch slave, refer to cylinder => [ Clutch System, Bleeding ] 02XA Transmission

• Disconnect from hose/line assembly, refer to => [ Disconnect clutch slave cylinder from hose/line assembly ]

• Brake fluid must not come into contact with transmission

12 Bleeder valve

• Tighten to 4.5 Nm

• Observe work sequence when bleeding, refer to => [ Clutch System, Bleeding ] 02XA Transmission

• A broken bleeder valve can be removed with a 3 mm hex key

13 Dust cap

14 Clip

• To remove the line, pull the clip out to the stop, refer to => [ Disconnect clutch slave cylinder from hose/line assembly ]

15 Bracket

• For hose/line assembly

• Secured at transmission with clutch slave cylinder

16 Internal hex bolt - 25 Nm

• Clutch slave cylinder to transmission

• Self-locking

• Replace

17 Retaining clip

18 Gasket

19 Bolt

• For brake fluid reservoir

Pry off mount - A - in direction of - arrow -





Press master cylinder actuator rod into mounting - A - (direction of - arrow -)





Disconnect clutch slave cylinder from hose/line assembly





Removing

- To remove hose/line assembly, pry out clip - A - to stop using a screwdriver. Only then can hose/line assembly be pulled out.

Installing

- Press in securing clip - A - to stop.

- Push hose/line assembly - B - into clutch slave cylinder until the line audibly engages.

- Verify by pulling on hose/line assembly.