Hydraulic System, Assembly Overview
Hydraulic system, assembly overview - 6 Spd. Manual Transmission 02X All Wheel Drive
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
4 - Grommet
5 - Mounting bracket
6 - Clutch pedal
7 - Master cylinder
^ Do not remove clip - arrow A - or seal - arrow B -.
^ To remove line/hose assembly, pull out clip - arrow A -, 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.
^ 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.