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Master Cylinder - LHD: Installation

NOTE: Vehicles equipped with a 1.6/2.0/2.4L (Non-Turbo) engine have one-piece master/slave cylinder assemblies. If the master cylinder requires replacement, the master/slave cylinders must be replaced with a two-piece "quick-connect" system. If the slave cylinder requires replacement, the slave cylinder is serviced separately.
NOTE: Replacement master cylinder assemblies come pre-filled with fluid. No fluid service or system bleeding should be required, unless the hydraulic system has lost an excessive amount of fluid and has ingested air into the master or slave cylinder assembly.
  1. Install clutch master cylinder into position (Figure ) and carefully route hydraulic pipe into position as removed.
  2. Install clutch master cylinder reservoir (Figure ).
  3. Install and torque two clutch master cylinder-to-dash panel retaining nuts (Figure ) to 15 N.m (130 in. lbs.) torque.
  4. Loosen master cylinder pushrod adjustment screw (Fig 1 ).
    Fig 1: Adjusting Clutch Pedal
    G02663350Courtesy of DAIMLERCHRYSLER CORP.
  5. Connect clutch master cylinder rod to clutch pedal pin. An audible "click" should be heard. If damaged, replace nylon retainer.
  6. Adjust clutch pedal position. Gently lift upward on clutch pedal. Tighten adjustment screw to 6 N.m (55 in. lbs.) torque.
  7. Install brake booster into position. Connect push rod to brake pedal pin (Figure ).
  8. Install and torque brake booster-to-cowl panel nuts (Figure ) to 34 N.m (300 in.lbs.). Install push rod retaining clip.
  9. Replace stop lamp switch. Refer to Stop Lamp Switch Removal and Installation.
  10. Install lower instrument panel bezel (Figure ).
  11. Install PDC bracket into position.
  12. Raise vehicle on hoist.
  13. Install clutch master cylinder hydraulic pipe into left rail retainer (Figure ).
  14. If master cylinder is being replaced, also install service replacement slave cylinder. If original master cylinder is being re-used, install slave cylinder as shown in (Figure ) (Figure ).
  15. Diesel and Turbo Models:  Connect hydraulic pipe to clutch slave cylinder (Figure ). An audible "click" should be heard. Verify connection by pulling outward on connection.
  16. Lower vehicle.
  17. Connect battery negative cable.
  18. Install air cleaner assembly (Figure ).
  19. Verify that reservoir is full. Top off with DOT 3 brake fluid if necessary.
  20. Actuate clutch pedal a minimum of ten times to allow any air ingested into the system to vent to the master cylinder reservoir. If residual air becomes trapped in the system, it is necessary to bleed the clutch hydraulic system. (Refer to CLUTCH - STANDARD PROCEDURE  )
  21. Verify proper clutch release system operation.
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