Clutch Master Cylinder: Service and Repair

Replacing the clutch master cylinder

Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.

Removal

Removing engine compartment components





Remove:
- the battery
- the air cleaner (ACL) housing and the fresh air intake hose.





Remove:
- the screws for the air filter bracket and the holders for the clutch pipe. Let the bracket hang loose
- the fuse / relay unit. Push the fuse / relay unit to one side (applies to cars from 1996-), in order to see the work area more clearly.

Draining the brake fluid reservoir




Drain the brake fluid reservoir so that level is slightly below the MIN marking.
Disconnect the hose from the brake fluid reservoir to the clutch master cylinder. Wipe up any spilled brake fluid.
Disconnect the two drain hoses from the mounting in the member and firewall.
Remove the lock for the clutch pipe. Pull the clutch pipe out of the master cylinder. Protect the opening from dirt.

Removing the panel





Remove:
- the panel under the dashboard on the driver's side
- the knee bolster (if applicable).
Cut the firewall insulation at the dotted markings. Push the insulation to one side so that the nuts holding the power brake booster to the firewall are exposed.

Removing the master cylinder





Note! Applies to certain versions only: Unhook the position sensor from the clutch pedal.

Remove:
- the lock for the push rod on the clutch pedal. Unhook the push rod from the pedal
- the nuts for the power brake booster
- the screw and the nut for the master cylinder in the firewall.




Pull out the power brake booster so that its studs are supported against the firewall.
Remove the clutch slave cylinder.

Installation

Installing the master cylinder




Check and transfer the inlet hose for the brake fluid to the new clutch cylinder.
Position the cylinder on the firewall. Locate the studs for the power brake booster in the firewall.

Caution! Check that the drainage pipe / hose is between the master cylinder and the frame member.




Install a new locking screw and lock nut on the cylinder. Tighten to 25 Nm .
Connect the push rod to the clutch pedal. Install the locking clip. Ensure that locking clip is seated in the groove on the shaft journal.
Install new lock nuts on the power brake booster. Tighten to 25 Nm .

Note! Applies to certain versions only: Install the position sensor on the clutch pedal.

Press the insulation into place against the firewall. If necessary secure the insulation using contact adhesive.

Installing the panel





Install:
- the knee bolster (if applicable). Tighten to 20 Nm
- the panel under the dashboard.

Installing hoses




Install a new sealing ring on the clutch pipe. Connect the pipe and press the lock into place.
Connect the hose to the brake fluid reservoir.
Connect the drain hoses to the terminals in the firewall and the frame member.

Installing engine compartment components





Install:
- the screws for the bracket for the air cleaner (ACL) housing

Note! Do not forget the holder for the clutch pipe.

- the fuse / relay unit in the holders (applies to cars from 1996-).
Bleed the clutch.
Fill the brake fluid reservoir completely. Use Volvo Genuine parts brake fluid only.
After bleeding, check and top up the level if necessary.





Install:
- the air cleaner (ACL) housing assembly and the fresh air intake hose
- the battery.