Clutch Pedal
Clutch pedal
Special tools:
999 7172 Wrench 999 7172 Wrench
Note! The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.
Preparatory work
Removing the battery and battery box
Remove:
- the battery. See: Battery Removal and Replacement
- the bolts, x3 (1)
- the connector, x1
- the battery box (2).
Removal
Removing the intake manifold
Note! Applies only to 5 cylinder turbocharged engines.
Remove the intake manifold to the turbocharger and seal the openings.
Removing the soundproofing panel, engine compartment
Remove:
- the clip, x1
- the plastic nut, x1
- the soundproofing panel.
Disconnecting the position sensor
Note! Applies to vehicles with outer position sensor.
Unplug the connector to the clutch position sensor.
Removing the hydraulics
Pull out the lock pin and detach the clutch line.
Note! Be prepared with paper to prevent spillage.
Press in the lock button and carefully pull away the supply line from the master cylinder.
Temporarily tie up the supply line.
Note! Make sure that the end of the hose is secured higher than the level in the reservoir.
Removing the soundproofing panel
Remove the soundproofing panel on the driver's side in accordance with: Instrument panel lower Instrument Panel Lower.
Removing the pedal position sensor
Note! Applies to vehicles with inner pedal position sensor
Remove the inner pedal position sensor in accordance with: Position sensor clutch pedal passenger compartment Service and Repair Position sensor clutch pedal passenger compartment, M56, MMT6, M66 Service and Repair.
Removing the contact breaker for the immobilizer
Note! Applies to vehicles with immobilizer.
Remove the immobilizer in accordance with:.
Detaching the ball joint
Hint: In order to avoid any spillage, lay paper at the pipe connections and first drain the master cylinder of the remaining brake fluid by pressing the pedal down several times.
Press in the ball joint's lock pins, one on each side of the pedal arm.
Removing the pedal assembly
Hint: To the top nut, use a ring wrench with a locking function.
Remove the nuts, x4.
Pull the pedal assembly out approx. 50 mm.
Separate the master cylinder from the pedal assembly, use: 999 7172 Wrench 999 7172 Wrench.
Turn counterclockwise.
Remove:
- the pedal assembly
- the master cylinder.
Hint: Press the pedal down while removing the pedal assembly.
Installation
Note! For tightening torques, see Specifications. [1][2]Clutch, M/T.
Preparations for installation
Always replace the sound insulation when installing the master cylinder.
Hint: Check that the lock pin for the clutch line is fitted correctly.
Installing the pedal assembly and master cylinder
Note! Carefully maneuver the master cylinder into place through the hole in the cowl panel. Following which, maneuver the pedal assembly into place, and fit the master cylinder with the pedal assembly.
Assemble the master cylinder and pedal assembly by turning clockwise, use: 999 7172 Wrench 999 7172 Wrench.
Install the pedal assembly into its location.
Fit the nuts, M8 x4. Tighten.
Installing the ball joint
Carefully press the ball joint into the pedal arm, check that both lock pins lock securely.
Installing the contact breaker for the immobilizer
Note! Applies to vehicles with immobilizer.
Install the immobilizer in accordance with:.
Installing the pedal position sensor
Note! Applies to vehicles with inner pedal position sensor
Install the inner pedal position sensor in accordance with: Position sensor clutch pedal passenger compartment, M56, MMT6, M66 Service and Repair Position sensor clutch pedal passenger compartment Service and Repair.
Installing the soundproofing panel
Install the soundproofing panel on the driver's side in accordance with: Instrument panel lower Instrument Panel Lower.
Installing the clutch line
Press the clutch line into the master cylinder.
Press in the lock pin and check that the line is locked securely.
Press in the supply line to the master cylinder.
Check that the line is locked securely.
Connecting the position sensor
Note! Applies to vehicles equipped with outer position sensor.
Attach the connector to the clutch position sensor.
Finishing
Bleeding the clutch
Note! Unscrew the bleed screw until drops start to form. The version uses a rubber gasket instead of a cone.
Bleed the clutch.
Checking the brake fluid
Check the brake fluid level.
Only use Volvo original brake fluid DOT 4+ when filling.
Installing the soundproofing panel, engine compartment
Install:
- the clip, x1
- the plastic nut, x1
- the soundproofing panel.
Installing the intake manifold
Note! Applies to 5 cylinder turbocharged engines.
Remove the seals. Install the intake manifold to the turbocharger.
Installing the battery and battery box
Install:
- the connector, x1
- the battery box (2)
- the bolts (1), x3
- the battery in accordance with: Battery Removal and Replacement.
Checking the function
Check the function.