Assembly overview - hydraulic system Page 1 of 2

Assembly overview - hydraulic system

1 - Brake fluid reservoir
2 - Supply hose
 For master cylinder.
3 - Pipe/hose line
 Disconnecting from
master cylinder and
installing → Anchor.
 Disconnecting from
slave cylinder
→ Fig..
 Allocation for LHD
and RHD vehicles
via → Electronic
parts catalogue
(ETKA).
4 - Grommet
5 - Mounting bracket
6 - Clutch pedal
 For LHD vehicles
→ Chapter.
 For RHD vehicles
→ Chapter.
7 - Hexagon socket head
bolt, 20 Nm
8 - Pin
 Always renew
 Lubricate with grease
-G 000 450 02-.
9 - Master cylinder
 Removing and
installing → Chapter
 Do not operate clutch pedal after slave cylinder has been removed.
 Clip -arrow A- and seal -arrow B- must not be removed.
 To remove hose/pipe line, pull out clip -arrow A- only to stop → Anchor.
10 - Gearbox
11 - Slave cylinder
 Do not operate clutch pedal after slave cylinder has been removed.
 Brake fluid must not be allowed to get onto gearbox.
 Removing and installing → Chapter
 After working on hydraulic clutch mechanism, bleed clutch system → Chapter.
12 - Bleeder valve, 4 Nm
 Bleeding clutch system → Chapter
13 - Dust cap
14 - Clip
 Pull clip out to stop to remove pipe/hose line.
15 - Retainer

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Assembly overview - hydraulic system Page 2 of 2

 For pipe/hose line.

 Secured to gearbox with slave cylinder.
16 - Hexagon socket head bolt, 25 Nm
 Slave cylinder to gearbox
 Self-locking.
 Always renew
17 - Hexagon nut, 2 Nm
18 - Seal

Disconnecting slave cylinder from pipe/hose line

Removing
– To remove pipe/hose line, pry out clip -A- to stop
using a screwdriver. Only then can you pull out the
pipe/hose line.
Installing
– Press in clip -A- to stop.
– Push pipe/hose line -B- into slave cylinder until line
audibly engages.
– Test pipe/hose line by tugging on it.

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Removing Page 1 of 3

Removing
– First check whether a coded radio is fitted. If so, obtain anti-theft
code.
– With ignition switched off, disconnect battery earth strap
→ Electrical system; Rep. Gr.27.
– Lay a lint-free cloth in plenum chamber beneath supply hose from
brake fluid reservoir.
– Clamp off supply hose -A- to brake fluid reservoir
with hose clamp -3094-, pull hose off connecting
pipe of master cylinder and seal it.
– Remove grommet for supply hose -A- from
bulkhead.
– Pull out clip -C- to stop using screwdriver and then
pull out pipe/hose line -B- slightly.

– Remove bolt for brake fluid reservoir -1- and pull

off connector for brake fluid level warning contact
downwards.
The brake fluid reservoir need not be removed.

– Remove vacuum pipe to brake servo -1-.

– Unscrew the two Torx bolts -arrows-.
For clarity of illustration, brake fluid reservoir is
not shown.
To remove upper Torx bolt, swing brake fluid
reservoir slightly to side.
– Remove compartment on driver side → General
body repairs; Rep. Gr.70.

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Removing Page 2 of 3

Release master cylinder operating rod from clutch

pedal as follows:
– Insert commercially available needle nose pliers -1-
in indentation of clutch pedal.
– Compress mounting -arrow 2-.
– Pull clutch pedal gently into passenger
compartment.
– Pull operating rod and mounting out of clutch pedal
and into engine compartment in -direction of arrow-
.

– Unbolt master cylinder -arrow 1- from inside

passenger compartment -arrow 2-.
– Remove securing bolt -arrow 3- for mounting
bracket.
– Pull complete pedal cluster slightly into passenger
compartment.
– Remove master cylinder.

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Removing Page 3 of 3

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Installing Page 1 of 3

Installing
Installation is performed in the reverse order of removal; when doing
this, note the following:
– Insert master cylinder so that seal -1- and washer
make contact behind mounting bracket.
– Tighten bolts -2- to specified torque.
– Press connecting pipe -3- with guide -arrow A- into
notch -arrow B- on mounting bracket.

A second mechanic is required for the next step.

– Push complete pedal cluster forwards to bulkhead
and insert bolt -1-.
At the same time, second mechanic must guide
pipe/hose line into master cylinder from plenum
chamber.

– Tighten securing bolts -arrows- for master brake

cylinder and brake servo.
– Install vacuum pipe to brake servo -1-.

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Installing Page 2 of 3

– Then tighten securing bolt -1- for brake fluid

reservoir.
– Push connector onto brake fluid level warning
contact on brake fluid reservoir.

– Press in clip -C- in direction of arrow to stop.

– Push pipe/hose line -B- into master cylinder until
line audibly engages.
– Test pipe/hose line by tugging on it.
– Insert grommet -D- for supply hose -A- into
bulkhead.
– Push supply hose -A- onto connecting pipe of
master cylinder to stop.
– Remove hose clamp -3094-.

– Tighten bolt -1- for securing pedal cluster to dash

panel carrier.

Join master cylinder operating rod to clutch pedal as

follows:
– The retainer -A- must be fitted to the master
cylinder operating rod -arrow-.

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Installing Page 3 of 3

– Insert retainer in guide on clutch pedal and push

clutch pedal towards bulkhead until it engages,
ensuring that it locks properly.
– To ensure that retainer is locked correctly, pull
clutch pedal slightly into passenger compartment
and push both ends of retainer into clutch pedal
using a screwdriver.
– Bleed clutch system after installing master cylinder
→ Chapter.

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