Table of contents: Hydraulic clutch system ↓ Disconnecting and connecting the… ↓ Removal and installation the main… ↓ Removal and installation of cyl.… ↓
Hydraulic clutch system
Follow the instructions for removing and installing the clutch master and slave cylinders.
1. Clutch slave cylinder: After removing, do not press the clutch pedal; after working on the hydraulic clutch drive, bleed the clutch drive; brake impact. liquids on the gearbox are not allowed.
2. Bleed nipple: 5.5 Nm; follow the procedure when pumping; a broken bleed nipple can be unscrewed with an internal hex key (3 mm).
3. Cap.
4. Pipe-hose line: with frequency modulator.
5. Mounting clip.
6. Nozzle.
7. O-rings: Replace if damaged; install by wetting the brake. liquid.
8. Feed hose: for main cyl. clutch; with built-in sealing nozzles; in case of damaged seals. replace the feed hose on the nozzles.
9. Brake reservoir. liquids.
10. Locking clamp: To remove the hose line, pull it out as far as it will go.
11. Clutch master cylinder: after working on the hydraulic clutch drive, bleed the clutch drive.
12. Pipeline.
13. Pipeline holder: attached to the control panel.
14. Bolt: 20 Nm.
15. Sealing ring: replace if damaged; install by wetting the brake. liquid.
16. Locking clamp: To remove the hose line, pull it out as far as it will go.
17. Bolt: clutch slave cylinder to gearbox; 20 Nm.
Disconnecting and connecting the pipe and hose line
Unlock the locking bracket "A" with a screwdriver and pull it out until it stops. Disconnect the pipe and hose line.
Connection
If damaged, replace the seal. ring. Press the locking clip "A" until it stops. Insert the pipe-hose line into the branch pipe until it clicks into place. To check, pull the pipe-hose line.
Removal and installation the main cyl. clutch
Disconnect the ground wire "2" from the battery terminal.
Remove the junction box.
Clamp the brake fluid supply hose. fluid "2" to the brake reservoir. fluid using the hose clamp "3094" on the clutch master cylinder "1", remove and plug the hose. To remove the locking bracket "3", you need to unlock it with a screwdriver and pull it out until it stops. Disconnect the pipe and hose line "4". Connector "pos. 5" remains connected for now.
Remove the servo spring. Remove locking pin "1" from clutch pedal "3". Ignore pos. 2- and -arrows A, B-.
Unlock the clutch master cylinder using the open-end spanner SW 32 "3355" in the "direction of the arrow".
Remove clutch master cylinder "1" and route it through the engine wiring harness opening. Unlock and disconnect plug connection "5".
Installation
If damaged, replace the seal. ring. Connect the plug connection "5". Install the clutch master cylinder "1". Route the clutch master cylinder into the footwell "direction of arrow A". In doing so, secure it with the 32 mm open-end wrench "3355" in the "direction of arrow B".
Install locking pin "4". The protrusion on the pin "arrow B" should enter the groove on the clutch pedal. "Pos. 1, 2, 3" and "arrow A" are not taken into account. Install the servo spring.
Press the locking clip "3" until it stops. Insert the pipe-hose line "4" into the clutch slave cylinder until it clicks into place. To check, pull the pipe-hose line. Push on the brake supply hose. fluid "2" until it stops. Remove hose clamp "3094". Bleed air from the clutch assembly. Installation in reverse order. Install the junction box. Take into account the measures required after connecting the battery.
Removal and installation of cyl. clutch booster
Follow the instructions for removing and installing the clutch master and slave cylinders. Brake hit. liquids on the gearbox are not allowed. If necessary, clean the gearbox housing. If present, remove the rear noise insulation "2".
To remove the locking bracket "2", you need to unlock it with a screwdriver and pull it out until it stops. Remove the hose line from the working cylinder. clutch and close it. Unscrew bolt "3", remove clutch slave cylinder "1" back.
Installation
Installation in reverse order. If damaged, replace the seal. ring. When the working cylinder is warped. during installation, there is a risk that the push rod will pass the clutch release lever. Press down on the clutch slave cylinder "1" until the mounting bolt "3" can be easily installed. Press the locking clip "2" until it stops. Insert the hose/pipe line into the clutch slave cylinder until it clicks into place. To check, pull the pipe-hose line. Remove air from the clutch assembly. Install (if available) rear noise insulation screen.
(The original version of the article is posted on the website AUDIMANUAL.RU)