Clutch Master Cylinder: Service and Repair

1. Remove:
- Air Cleaner (ACL) and intake pipe.
Timing valve from ACL. (Turbo models only).
- Screws holding bracket to ACL.
- Cable tie to drain hose (move to one side).





2. Disconnect hose from brake fluid reservoir.
- Put absorbent paper under clutch master cylinder to protect paintwork.
- Collect brake fluid from reservoir and hose in a suitable container.
Disconnect pipe from clutch master cylinder.
Late models (left hand drive) only:
- Disconnect snap-on coupling locks.
- Disconnect pipe from clutch master cylinder.





3. Remove clutch master cylinder
- Remove panel under dashboard.
Cars with SRS: Remove kneeguard also.
- Fold back carpet.
- Remove clip holding clutch master cylinder pushrod to clutch pedal.
- Remove nut and bolt securing clutch master cylinder to firewall.
- Remove clutch master cylinder.
4. Install new clutch master cylinder
- Transfer brake fluid supply hose to the new clutch master cylinder.
- Apply a little silicone grease to the clutch master cylinder pushrod lug.
- Install clutch master cylinder, nut and bolt.
Tighten to: 25 Nm.
- Install clip holding pushrod to clutch pedal.
Cars with SRS: Install kneeguard.
Tighten to: 20 Nm.
- Install panel under dashboard.
- Relay carpet.
5. Install:
- Clutch master cylinder pipe.

NOTE: Snap-on coupling pipes: fit new O-ring.

- Brake fluid reservoir hose.
- Drain hose and cable tie.





6. Fill up with fresh brake fluid and bleed system via clutch master cylinder bleed nipple.

NOTE: Use only genuine Volvo brake fluid, DOT+.

7. Install:
- Bracket retaining screws to ACL.
- ACL and intake pipe.
- Timing valve to ACL. (Turbo models only.)