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Master Cylinder: Installation

NOTE: Vehicles equipped with a 1.6/2.0/2.4L (Non-Turbo) engine have one-piece master/slave cylinder assemblies. If the master cylinder requires replacement, the master/slave cylinders must be replaced with a two-piece "quick-connect" system. If the slave cylinder requires replacement, the slave cylinder is serviced separately.
NOTE: Replacement master cylinder assemblies come pre-filled with fluid. No fluid service or system bleeding should be required, unless the hydraulic system has lost an excessive amount of fluid and has ingested air into the master or slave cylinder assembly.
  1. Install clutch master cylinder into position and carefully route hydraulic pipe into position as removed. See Figure.
  2. Install clutch master cylinder reservoir. See Figure.
  3. Install and torque two clutch master cylinder-to-dash panel retaining nuts to 15 N.m (130 in. lbs.) torque. See Figure.
  4. Loosen master cylinder pushrod adjustment screw.
    Fig 1: Locating Adjustment Screw
    G01857142Courtesy of DAIMLERCHRYSLER CORP.
  5. Connect clutch master cylinder rod to clutch pedal pin. An audible "click" should be heard. If damaged, replace nylon retainer.
  6. Adjust clutch pedal position. Gently lift upward on clutch pedal. Tighten adjustment screw to 6 N.m (55 in. lbs.) torque.
  7. Install brake booster into position. Connect push rod to brake pedal pin. See Figure.
  8. Install and torque brake booster-to-cowl panel nuts to 34 N.m (300 in. lbs.). Install push rod retaining clip. See Figure.
  9. Replace stop lamp switch.
  10. Install lower instrument panel bezel. See Figure.
  11. Install PDC bracket into position.
  12. Raise vehicle on hoist.
  13. Install clutch master cylinder hydraulic pipe into left rail retainer. See Figure.
  14. If master cylinder is being replaced, also install service replacement slave cylinder. If original master cylinder is being reused, install slave cylinder as shown in illustration. See Figure.
  15. Diesel and Turbo Models:  Connect hydraulic pipe to clutch slave cylinder. An audible "click" should be heard. Verify connection by pulling outward on connection.
  16. Lower vehicle.
  17. Connect battery negative cable.
  18. Install air cleaner assembly. See Figure.
  19. Verify that reservoir is full. Top off with DOT 3 brake fluid if necessary.
  20. Actuate clutch pedal a minimum of ten times to allow any air ingested into the system to vent to the master cylinder reservoir. If residual air becomes trapped in the system, it is necessary to bleed the clutch hydraulic system. See STANDARD PROCEDURE-BLEEDING CLUTCH HYDRAULIC CIRCUIT .
  21. Verify proper clutch release system operation.
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