Clutch Control, Servicing

5 Speed Manual 02J

Clutch Controls, Servicing






Note:

- Disconnect battery Ground strap.
- Obtain radio code for vehicles with coded radio.
- Lubricate all bearings and contact surfaces with poly-resin grease, Part No. G 052 142 A2.






I - Pedal Cluster, Assembly Overview

1 Bulkhead
- With mounting for mounting bracket and master cylinder
2 Seal
- Always replace
3 Mounting bracket
- For mounting clutch pedal
4 Bolt
5 Mounting bracket
- For mounting accelerator and brake pedals
6 Self-locking hex nut
- 25 Nm (18 ft. lbs.)
- Always replace
7 Connecting plate
8 Self-locking hex nut
- 25 Nm (18 ft. lbs.)
- Always replace
9 Mounting Bushing
10 Fulcrum pin
11 Clutch pedal
12 Retainer
13 Self-locking hex nut
- 25 Nm (18 ft. lbs.)
- Always replace
14 Master cylinder
15 Supply hose
16 Over-center spring
17 Over-center spring mounting
- Install in mounting bracket
18 Stop
- For clutch pedal
19 Self-locking hex nut
- 25 Nm (18 ft. lbs.)
- Always replace
20 Clutch Pedal Switch
- For cruise control system

II - Hydraulic System, Assembly Overview






1 Brake fluid reservoir
2 Supply hose
3 Master cylinder
4 Retainer
- Replace only with master cylinder removed
5 Clutch pedal
6 Self-locking nut
- 25 Nm (18 ft. lbs.)
- Always replace
7 O-ring
- Coat with brake fluid
- Pull onto line/hose connection
8 Line/hose assembly
9 Bracket
- Secured to bodywork
10 Dust cap
11 Bleeder valve
12 Slave cylinder
Remove the following components before removing slave cylinder:
- Gear selector cable from gear selector lever
- Relay lever and actuating arm for gate selector cable
- After installing adjust gear selector mechanism
13 Bolt
- 25 Nm (18 ft. lbs.)
- With collar
14 Transmission
15 Clip
16 O-ring
- Coat with brake fluid
- Pull onto line/hose connection
17 Cable support bracket
18 Hose bracket
- Secure to cable support bracket -17-
19 Clip

Fig.1 Pry retainer -A- off in direction of arrow






Fig.2 Press master cylinder operating rod in retainer -A- in direction of arrow.