Master Cylinder

Master cylinder, LHD
To remove
1. Cover the left-hand wing.
2. Remove the battery cover and the battery.





3. V6 diesel engine: Remove the turbocharger heat shield.
4. Remove the main fuse box and place it to one side.
5. Drain the brake fluid reservoir. Use 88 19 096 Bleeding equipment.
Then connect the brake bleeder to the bleed nipple on each front brake caliper and draw out the remaining brake fluid.
6. Manual gearbox: Disconnect the clutch fluid hose from the brake fluid reservoir.





7. For change of master cylinder only:
Remove the brake fluid reservoir. Withdraw the reservoir straight upwards.
8. Clean around the brake pipes.
Disconnect the brake pipes.
9. Remove the two master cylinder retaining nuts and lift out the master cylinder.

To fit
1. Fit the master cylinder to the brake servo unit. Make sure the O-ring is in good condition and assumes the correct position.





2. Fit the brake lines in place.
Tightening torque 16 Nm (12 ft. lbs.)
3. Fit the brake fluid reservoir. Lubricate the connections with brake grease 49 04 108 to facilitate fitting.
4. Manual gearbox: Connect the clutch fluid hose to the brake fluid reservoir. Fit the hose clip facing upwards.
5. Bleed the brake system.
6. Check the system for leaks.
7. Fit the main fuse box in place.





8. V6 diesel engine: Fit the turbocharger heat shield.
9. Fit the battery and the battery cover.

Master cylinder, RHD
To remove
1. V6 TiD: Remove the upper intake manifold.





2. V6 TiD: Remove the upper engine cover.
3. Drain the brake fluid reservoir. Use 88 19 096 Bleeding equipment. Then connect the brake bleeder to the bleed nipple on each front brake caliper and draw out the remaining brake fluid.
If changing the master cylinder: Remove the brake fluid reservoir.
4. Disconnect the brake pipes and plug them.





5. Remove the two master cylinder retaining nuts and lift out the master cylinder.

To fit
1. Fit the two master cylinder retaining nuts.
Tightening torque: 25 Nm (18 ft. lbs.)





2. Connect the brake pipes. Make sure the pipes are positioned correctly in their clips.
Tightening torque: 16 Nm (12 ft. lbs.)
3. If the master cylinder has been changed: Fit the brake fluid reservoir.
4. V6 TiD: Fit the upper engine cover.





5. V6 TiD: Fit the upper intake manifold.
6. Bleed the brake system.