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mounted in-line with and just forward of the
clutch pedal. The operating cylinder is
mounted within a housing on top of the
transmission. The fluid reservoir is located in
the engine compartment and is mounted on
the left-hand side near the bulkhead. No
settings or specific procedures are given by
the manufacturer at the time of writing.
Maintenance
(hydraulic clutch) ¡
7 Periodically check the fluid level in the
reservoir. If the level has dropped, top it up
with the specified fluid. The fluid level must
not be allowed to drop below the MIN level
mark on the side of the reservoir (photos). If
the fluid level drops by a significant amount, it
is indicative of a leak in the hydraulic circuit
and this must therefore be traced and
repaired at the earliest opportunity.
8 Inspect the fluid lines and connections for
security and any signs of leaks.
Clutch master cylinder -
removal, overhaul
and refitting #
9 If the cylinder is to be dismantled, it will first
be necessary to obtain a cylinder repair kit.
Start by detaching and removing the trim
panel from the underside of the facia on the
driver’s side.
10 Place a suitable covering over the floor
carpet to prevent staining in the event of fluid
spillage. Clamp the fluid supply hose at the
master cylinder end, then unscrew the
retaining clip and detach the hose from the
cylinder. Position the hose out of the way and
with its end pointing up.
11 Detach the operating rod clevis from the
brake pedal.
12 Unscrew and detach the hydraulic pipe to
the operating cylinder from the master
cylinder (photo).
13 Undo the two retaining nuts and withdraw
the master cylinder.
14 To dismantle the cylinder, prise free and
pull back the dust boot, extract the retainer
and withdraw the operating rod.
15 Invert the cylinder and shake free the
piston and seal assembly. If it is stuck inside
the cylinder, apply moderate air pressure
(from a foot pump) into the tail end and catch
the assembly in a clean cloth as it is ejected.
16 Remove the seals noting their orientation.
Clean all components in methylated spirits or
new hydraulic fluid. If the cylinder is damaged,
scored or badly worn it must be renewed. The
seals must always be renewed once they are
removed.
17 Assemble the new seals to the piston and
lubricate the cylinder, seals and piston
assembly with new hydraulic fluid (of the
specified type) before assembling them.
Ensure that the seals are fitted the correct
way round (as noted during removal).
18 Renew the dust boot, fit and secure the
operating rod into position with the retainer,
then refit the dust boot over the cylinder.
19 If the intake pipe connector was removed,
this must be refitted using a new seal.
20 Refit the cylinder in the reverse order of
removal. Connect and hand tighten the
hydraulic pipe to the operating cylinder before
fully tightening the cylinder securing nuts. The
hydraulic pipe can then be fully tightened.
21 Reconnect the fluid supply hose to the
cylinder and tighten the retaining clip to
secure. Release the clamp.
22 Top up the clutch fluid level in the
reservoir then bleed the system as described
later in this Section.
Clutch operating cylinder -
removal, overhaul
and refitting ¢
23 If the cylinder is to be dismantled once it
is removed, it will first be necessary to obtain
a cylinder repair kit. Access is much improved
by first detaching the appropriate ducts and
hoses from the areas directly above the
cylinder, on top of the transmission/clutch
housing.
24 To avoid excessive fluid loss when the
hydraulic line is detached from the operating
cylinder, remove the filler cap from the
reservoir, place a clean piece of polythene
sheet over the filler neck and refit the reservoir
cap.
Supplement: Revisions and information on later models 13•93
Fig. 13.88 Exploded view of the hydraulic clutch components (Sec 11)
1 Filler cap
2 Fluid reservoir
3 Hose
4 Master cylinder
5 Cover
6 Clip
7 Bracket
8 Hose
9 Operating cylinder
10 Bracket
11 Circlip
12 Operating lever
11.12 Clutch master cylinder and hydraulic
pipe connections
11.7B Topping up the fluid level in the
clutch fluid reservoir
11.7A Clutch hydraulic fluid reservoir
showing MIN and MAX markings
13