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Master Cylinder: Installation: Installation-LHD

  1. Install the master cylinder into position on the dash panel.
  2. Install the self-docking connector bracket.
  3. Install the master cylinder retaining nuts onto the master cylinder studs. Tighten the nuts to 11 N.m (100 in. lbs.).
  4. Route the hydraulic tube as noted upon removal.
  5. Connect the master cylinder hydraulic line to the slave cylinder hydraulic line. An audible click should be heard. Verify the connection by pulling outward on the master cylinder line.
  6. Install the master cylinder remote reservoir onto the dash panel.
  7. Install the reservoir retaining screws. Tighten the screws to 11 N.m (103 in. lbs.).
  8. Install the brake booster.
    CAUTION: Inspect the clutch master cylinder push rod plastic retainer for damage. If it is damaged (broken/cracked), it MUST be replaced.
  9. Loosen the push rod adjustment screw. (Fig 1).
    Fig 1: Loosening Clutch Master Cylinder Push Rod Adjustment Screw
    G01032521Courtesy of DAIMLERCHRYSLER CORP.
  10. Install the push rod onto the pedal pin.
  11. Gently lift clutch pedal upwards until the clutch pedal fully depresses the upstop switch. Torque adjustment screw to 6 N.m (55 in. lbs.).
  12. Install the ABS module/purge solenoid, PDC, and air cleaner.
  13. Depress and release the clutch pedal a minimum of ten (10) times to allow any residual air in the system to be vented to the reservoir. If residual air becomes trapped in the system, bleed the clutch hydraulic system. (Refer to STANDARD PROCEDURE - BLEEDING CLUTCH HYDRAULIC CIRCUIT (LHD/RHD MODELS) ).
  14. Connect the negative battery cable.
  15. Top off clutch master cylinder reservoir with DOT 3 brake fluid.
  16. Verify correct clutch operation.
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