R.H.D.

Master cylinder, replacing

Special tools:
981 4071 STRAIGHTENING TOOL 981 4071 Straightening Tool

Removal

Removing the torque rod
Remove the torque rod. See Brake fluid reservoir, replacing Service and Repair.

Disconnecting the connectors





Remove the connectors on / at:
- the brake fluid reservoir
- the power brake booster
- the wheel arch.
Push the oil hose with the connector to one side.

Removing the soundproofing panel




It is secured with three clips.
Pull the soundproofing panel straight downwards. At the same time, push the side panel one to side.

Removing components in the passenger compartment





Remove:
- the lock for the push rod on the clutch pedal. Move the push rod to one side
- the pedal position sensor from the clutch pedal: Pull it downwards at the clutch pedal and straight out from the firewall. Move the pedal position sensor to one side.

Removing the nuts for the clutch cylinder at the firewall





Note! Note the location of the bracket for the pedal position sensor so that it can be reinstalled correctly.

Blocking the hose as far as the clutch cylinder with a hose clip




Remove the lock for the clutch pipe.
Pull out the clutch cylinder slightly from the firewall.
If necessary:Remove the pipe from its clip at the firewall.

Remove the lock in the clutch cylinder
Use a weatherstrip tool 981 4071 STRAIGHTENING TOOL 981 4071 Straightening Tool. Press the reverse of the lock (see illustration) so that it comes out slightly. Then remove the lock using a small screwdriver.
Place paper underneath in case of brake fluid leakage.

Removing the master cylinder




Pull out and lift up the master cylinder. Rotate it half a turn.
Remove the clamp around the rubber hose. Disconnect the hose from the master cylinder.
Place paper underneath in case of brake fluid leakage.
Remove the cylinder.

Installation

Installing the master cylinder





Install:
- the rubber hose to the master cylinder. Secure the clamp around the hose
- the master cylinder on the firewall. Connect the clutch pipe to the cylinder. Lock the pipe with the catch.

Installing components inside the car





Install:
- the bracket for the pedal position sensor
- two new lock nuts for the master cylinder. Tighten to 25 Nm.

Note! Ensure that the ball on the bracket is downwards.

Install:
- the pedal position sensor on the bracket and on the push rod
- the soundproofing panel.

Finishing work in the engine compartment




Remove the hose clip.
Connect the connectors to the relevant switches.
Install the torque rod. See Brake fluid reservoir, replacing Service and Repair.
Install the clamp and the screw for the oil hose on the cross member mounting. Tighten to 10 Nm.

Bleed the clutch

Final check
Check the brake fluid level. Use only Volvo Genuine parts brake fluid (Volvo DOT 4+) when topping up.
Start the engine. Check that the clutch disengages when the gears are selected. Bleed the clutch if necessary.