B3FG2TK1 - 307

REMOVAL - REFITTING MASTER CYLINDER

1 - REMOVAL

Remove :

• the battery cover
• the battery
• the battery tray

Remove the filter from the brake fluid reservoir .

Drain the upper brake fluid reservoir (1) using a clean syringe .

Remove :

• the bolts (2)
• the upper brake fluid reservoir (1), after unclipping the pipe connecting it to the lower reservoir

Disconnect the connector (3) .

Drain the lower brake fluid reservoir (4) moving aside the supply pipe (5) from the clutch cable .

Close the clutch cable hole .

Uncouple the brake pipes (6) .

Blank the holes in the master cylinder and the brake pipes .

Remove :

• the nuts (7)
• the master-cylinder (8)

Tighten the master cylinder in a vice fitted with two soft jaws .

Remove the lower brake fluid reservoir (4) moving aside the retaining plates at (A) .

Retrieve the pin 9 .

2 - REFITTING

WARNING : always renew : the seal (10) .

NOTE : check the brake servo unit piston rod recess X = 19,85 ± 1,3 mm (this measurement is taken between the master cylinder support face and the head of the piston rod) .

Proceed in the reverse order to removal .

BLEED THE BRAKES .

EW6J4 ENGINE EW10J4 ENGINE DW10TD ENGINE DW10ATED ENGINE TU5JP4 ENGINE

BLEED THE HYDRAULIC CLUTCH CONTROL .

TU3JP ENGINE

BLEED THE HYDRAULIC CLUTCH CONTROL .

ALL MODELS

Tightening torque(s) :

• nut (7) : 2 da.Nm
• brake pipe unions : 1.5 da.Nm