1992 BMW 318i Hydraulic

117-
4



CAMSHAFT
TIMING
CHAIN

15
.
Remove
mounting
bolts
from
left
and
right
camshaft



4
.
Insta¡¡
and
hand-tighten
sprocket
mounting
bolts
.

sprockets
.

16
.
On
M42
engines,
remove
upper
bolt
on
right
side
chainguide
and
unbolt
lower
timing
chainguide
below
crank-
shaft
.

17
.
Remove
camshaft
sprockets
from
camshafts
together

with
chain
and
crankshaft
sprocket
.
NoteWoodruffkey
when
removing
crankshaftsprocket
.

CA
UTION-

The
crankshaft
must
not
be
allowed
to
rotate
when
the
timing
chaín
is
removed
.
The
pistons
can
contact
the
valves
.

Camshaft
timing
chain,
installing

(4-cylinder
engines)

Inspectal¡
sprockets
for
wear
or
damage
.
Inspect
the
chain
guide
and
tensioner
rails
for
grooves
caused
by
chain
contact
.

Replace
any
partthat
is
worn
.
If
any
of
the
sprockets
are
worn,
the
chain
and
sprocketsare
replaced
asan
assembly
.

The
procedure
outlined
below
assumes
that
the
camshafts
and
the
crankshaft
arelocked
in
the
TDC
installation
positionwithspecial
tools
(shown
earlier
in
Fig
.
5
and
Fig
.
6)
.

1
.
Install
timing
chain
to
crankshaft
sprocket,
then
slide
sprocket
on
crankshaft
whílealigníng
woodruff
key
.

2
.
Place
camshaft
sprockets
on
chain,
then
place
sprock-
ets
oncamshafts
so
that
arrows
on
sprockets
point
up
and
elongatedholes
in
sprockets
are
centered
lo
tapped
holes
in
camshafts
.
See
Fig
.
9
.

.
I

Pa
-
s



~_



a

Ge
..
.

0012509

5
.
On
M42
engine
:
Install
lowerchainguide
.

6
.
On
M44
engine
:
Remove
allen-head
retaining
screw
at
left
chain-guide
.
Turn
slotted-head
of
adjusting
sleeve

so
that
sleeve
contacts
cylinder
head
.
Then
install
and

tighten'allen-head
screw
fully
.
See
Fig
.
10
.

Fig
.
10
.
Left
upper
chain
guide
adjusting
sleeve
(arrow)
.
Note
cam-
shaft
position

CAUTION-

Different
hydraulic
chaintensioners
were
used
duringmanufacture,
depending
onengíne
type
.
See
Fig
.
11
.
Note
that
the
late
style
tensioner
canbe
retrofitted
to
the
earlier
engíne,
so
be
sure
to
identify
the
versíon
of
tensioner
ínstalled
as
ínstal-
lation
instructions
vary
between
the
two
.

7
.
On
M42
engine
:
Disassemble
chain
tensioner
by
strik-
ing
outer
sleeve
against
a
solid
object
.
This
will
release
snap
ring
and
tensioner
will
separate
.
See
Fig
.
12
.

8
.
On
M42
engine
:
Clamp
chain
tensioner
piston
in
vice
(soft
jaws)
.
Slowly
compress
piston,
making
sure
de-
tent
ring
fits
into
taper
of
outer
sleeve
.
If
necessary,
press
ends
of
detent
ring
together
.
Slowly
continueFig
.
9
.



Camshaft
sprockets
correctly
installed
with
arrows
pointing



pressing
tensioner
together
until
snap
ring
audibly
upand
bores
centered
to
tapped
holes
(M44
engine)
.



clicks
into
outer
sleeve
.
Measure
overall
length
of
ten-
sionerto
confirm
correct
assembly
:
68
.5
mm
(2
.7
in
.)
.

3
.
On
M44
engine
:
Place
cylinder
position
sensor
plate
on
intake
camshaft
sprocket
so
that
arrowonsensor
plate



NOTE-
points
up
.



The
¡ate-style
tensioner
on
the
M44
engine
can
be
ret-rofittedto
the
M42
engíne
.

CAMSHAFT
TIMING
CHAIN,
4-CYLINDER

M42
Engine

CL
(EM

Fig
.
11
.
Two
versionsof
hydraulic
chaintensioners
.
Original
chain
ten-
sioner
on
M42
engine
(top)
canbe
disassembled
.
Chain
ten-
sioner
on
M44
engine
(bottom)
cannot
be
disassembled
.
Note
differences
in
outer
sleeve
.
Also,
the
M42
tensioner
de-
tent
ring
groove
is
visible
when
tensioner
is
extended
(arrow)
.

Outer
sleeve
Spring

0013024a

Detent

ring

9
.
On
M44
engines
:
Clamp
tensioner
piston
in
vice
(soft

jaws)
and
squeeze
oil
from
it
.
Slowly
compress
piston

only
up
to
end
círclip
.
Repeat
procedure
twice
to
ensure

al¡oil
is
expelled
.
See
Fig
.
13
.

10
.
Insta¡¡
hydraulic
chain
tensioner
lo
cylinder
head
.
Usea
new
sealing
washer
on
tensionerplug
when
installing
.

Tightening
Torque

"
Chain
tensioner
to
cylinder
head
....
40
Nm
(30
ft-Ib)

11
.
On
M42
engines
:
Release
early-style
chain
tensioner
by
pressing
chain
guide
against
tensioner
until
it
un-

locks
and
expands
out
.

CAMSHAFT
TIMING
CHAIN



117-
5

0012507

Fig
.
13
.
When
reinstalling
chain
tensiones,
oil
in
tensioner
piston
must

first
be
expelled
by
compressing
piston
in
vise
.
When
com-
pressing
piston,
only
compress
up
to
and
circlip
(arrow)
.

Tightening
Torque

"
Chain
sprocket
lo
camshaft
flange
(M6)
..
.
..
.............
.
..
10
Nm
(89
in-lb)

13
.
Remove
crankshaft
locking
tool
from
bellhousing
and

camshaft
locking
tool
from
rear
of
cylinder
head
.

14
.
Install
lower
timingchain
cover
:

"
Insta¡¡
new
crankshaft
oil
seal
in
cover
.

"
Use
new
gaskets
when
installing
cover
.

"
Thoroughly
clean
profile
gasketgroove
and
all
gasket

sealing
surfaces
on
lowerchaincover
.

"
Apply
a
small
bead
of
silicon
sealer
(3-Bond
1209
or
Snap



equivalent)
lo
joint
corners
where
chaincover
meets

ring



0013024



head
and
block
.
See
Fig
.
14
.

"
Tap
cover
into
position
to
engage
locating
dowels
.

Fig
.
12
.
Disassembled
early-style
chain
tensioner
usadon
M42
en-



"
Tighten
cover
mounting
bolts
alternately
and
in
stages
.

gine
.

12
.
Check
that
chain
is
now
free
of
siack
.
Tighten
down

sprocket
mounting
bolts
.



where
chain
cover
meets
head
and
block
(arrows)
.
Fig
.
14
.
Apply
sealer
(3-Bond
1209
0
or
equivalent)
to
joint
corners

CAMSHAFT
TIMING
CHAIN,
4-CYLINDER

Fig
.
36
.
BMW
special
tool
no
.
11
2
300
installed
through
bellhousing
and
finto
flywheel
.

8
.
Remove
oil
line
fitting
from
VANOS
control
unit
.

NOTE-

Wrap
the
VANOS
oil
line
fitting
with
a
shop
to
absorb
leaking
oil
.

9
.
Using
hollow
bolt
and
seals
from
oil
supply
line,
instan

BMW
special
tool
no
.
11
3
450
(air
line
fitting)
and
con-
nect
a
supply
of
compressed
air
(30-115
psi)
to
VANOS

oil
fitting
.

10
.
Measure
and
record
distance
between
trigger
plate

edge
and
side
of
secondary
timing
chain
tensioner
.

See
Fig
.
37
.

Fig
.
37
.
VANOS
reference
measurement
(dimension
A)
between
trig-
ger
píate
(sender
gear)
and
side
of
secondary
chain
tensioner
.

CAMSHAFT
TIMING
CHAIN



117-
1
5

11
.
Disconnectharness
connector
from
VANOS
solenoid
.
Connect
BMW
special
tool
no
.
12
6
410
(electrical
test
lead)
to
VANOS
solenoid
connector
.

"
Connect
positive
(+)
test
lead
to
positive
(+)
terminal
ofbattery
Connect
negative
(-)
test
leadto
chassis
ground
.
solenoid
should
audibly
click
and
intake
cam-
shaft
should
advance
.

CA
UTION-

"
Be
sure
to
connect
the
test
hamess
polaritycor-
rectly
.
lf
the
polarity
is
reversed,
the
intemal
diode
in
the
VANOS
solenoid
will
be
destroyed
.
Although
the
solenoid
will
still
functionwith
a
faultydiode,
a
fault
code
may
be
set
in
the
ECM
memory
.

"
To
confirm
voltage
polarity,
turn
the
ignition
on
and
check
for
positive
(+)
batteryvoltage
at
the
terminal
corresponding
to
the
redlwhite
wire
in
the
main
harness
connector
.
Check
that
the
pos-
itive
terminal
(+)
in
the
main
connector
corre-
sponds
to
the
same
terminal
in
the
solenoid
connector
that
is
being
connected
to
the
battery
.

12
.
With
solenoid
actuated,
measure
and
record
new
dis-

tance
between
trigger
plate
edge
and
side'of
second-
ary
timing
chain
tensioner,
as
shown
in
Fig
.
37
.

13
.
Difference
between
first
measurement
(step
10)
andsecond
measurement
(step12)
should
be
at
least
8
.5
mm
(0
.3346
in
.)
.
lf
any
faults
arefound,
solenoid
may

be
faulty,
or
hydraulic
control
unit
may
be
faulty
or
incor-
rectly
installed
.

14
.
Check
VANOS
solenoid
byremoving
it
from
control
unit
.
Check
that
solenoid
plunger
and
control
unit

plunger
move
freely
.
Install
solenoid
using
tighteníng

torque
given
below
.

NOTE-

"
The
solenoid
is
available
asareplacement
part
.
lf
the
control
unit
plunger
is
sticking,
the
complete
control
unit
will
have
to
be
replaced
.

"lf
the
VANOS
system
does
not
advance
correctly
and
no
other
faults
can
be
found,
itis
possible
that
the
VANOS
control
unit
may
Nave
been
fnstalled
incor-
rectly-especially
if
the
camshaft
sprockets
have
pre-
víously
been
removed
for
other
repairs
.
Check
the
installation
by
removing
and
reinstalling
the
control
unit
as
described
later
.

VANOS
(VARIABLE
VALVE
TIMING)

2
.
Remove
cooling
duct
or
terminal
cover
from
rear
of
al-



2
.
Remove
air
cleaner
upper
section
with
mass
air
flow
ternator
.



sensor
.

3
.
Check
for
battery
voltage
between
ground
and
terminal



3
.
Remove
terminal
cover
from
rear
of
alternator
.
Discon
B+
at
back
of
alternator
.
Then
turn
ignition
on
and



nect
wiring
.
check
for
battery
voltage
between
terminal
D+
and
ground
.
See
Fig
.
3
.
lf
voltage
is
not
present
at
either



4
.
Remove
drive
belt
from
alternator
pulley
.
See
020
point,
check
wiring
for
faults
.



Maintenance
program
.

001
¡987
Fig
.
3
.



Terminal
B+
is
supplied
battery
voltage
directly
from
the
bat-
tery
.
Terminal
D+
is
supplied
battery
voltage
via
the
charge
warning
bulb
when
thekey
is
on
or
the
engine
is
running
.

4
.
lf
no
faults
are
foundup
to
thispoint,test
alternator
out-

put
using
a
load
tester
.

5
.
If
a
load
tester
is
not
available,
a
crude
output
test
can
be
done
by
running
engine
at
about
2000
rpmand
turn-
ing
on
electrical
loads
(fans,
lights
and
rear
window
de-
froster,
wipers)
.
With
al¡
accessories
on,
battery
voltage
should
be
above
12
.0
VDC
.

A
replacement
alternator
should
have
the
same
rating
as
the
original
.
Alternator
manufacturer
and
ampere
rating
are
normally
marked
on
the
alternator
housing
.
1
.
Disconnect
negative
(-)
battery
cable
.

CAUTION-

Prior
to
disconnecting
the
battery,
read
the
battery
disconnection
cautions
given
at
the
front
of
this
manual
on
page
vi¡¡
.

BATTERY,
STARTER,
ALTERNATOR



121-
5

6
.
Remove
upper
and
lower
mounting
bolts
and
lift
out
al-
ternator
.
See
Fig
.
4
.

NOTE
-

If
reusing
drive
belt,
mark
direction
of
rotation
on
belt
before
removing
.

5
.
On
M44
engine
with
hydraulic
belt
tensioner
:
Remove
tensioner
idler
pulley
(upper
roller)
from
alternator

bracket
.

Fig
.
4
.



Alternator
mounting
bolts
(arrows)
.

O



u
J
S
v~~

U

I



1
i
n
-12
.22

Alternator,
removing
and
installing



7
.
Installation
is
reverse
of
removal
.
Install
drive
belt
as

(4-cylinder
engine)



described
in
020
Maintenance
Program
.

Tightening
Torques

"
D+
vire
to
alternator
(M6
nut)
.
...
.
.
.
7
Nm
(53
in-lb)

"
B+
wire
to
alternator
(M8
nut)
..
.
.
.
.
.
13
Nm
(10
ft-Ib)

"
Pulley
to
alternator
(M16
nut)
...
..
..
60
Nm
(44
ft-Ib)

ALTERNATOR
SERVICE

121-
6



BATTERY
STARTER,
ALTERNATOR

Alternator,
removing
and
installing

(6-cylinder
engine)

A
replacement
alternator
should
have
the
same
rating
as

the
original
.
Alternator
manufacturer
and
ampere
rating
are

normally
marked
on
the
alternator
housing
.

1
.
Disconnect
negative
(-)
battery
cable
.

CAUTION-

Prior
to
disconnectiog
the
battery,
read
the
battery
disconnection
cautions
given
at
the
front
of
this
manual
onpage
viii
.

2
.
Remove
alternator
cooling
duct
and
air
filter
housing

assembly
from
car
.
Disconnect
wiring
from
rear
of
alter-

nator
.

3
.
Remove
radiator
cooling
fan
and
fan
shroud
.
See
170

Radiator
and
Cooling
System
.

4
.
Remove
alternator
drive
belt
from
alternator
pulley
.
On

engines
with
hydraulic
belt
tensioner,
remove
tensioner

idler
pulley
(upper
roller)
from
alternator
bracket
.
See

Fig
.
5
.

ALTERNATOR
SERVICE

Fig
.
5
.



Pry
off
cover
from
tensioner
and
then
lever
tensioner
clock-
wise
to
release
belt
tension
.
Remove
upper
roller
(A)
once
belt
ís
removed
.

NOTE-

If
reusing
drive
belt,
mark
direction
of
rotation
on
belt

before
removing
.

5
.
Remove
upper
and
lower
mounting
bolts
and
lift
out
al-

ternator
.

6
.
Installation
is
reverse
of
removal
.
Note
locating
notches
on
tensioner
idler
pulley
(upper
roller)
alternator
brack-

et
when
installing
pulley
.

Tightening
Torques

"
D+
wire
to
alternator
(M6
nut)
.......
7
Nm
(53
in-lb)

"
B+
wireto
alternator
(M8
nut)
.......
13
Nm
(10
ft-Ib)

"
Pulley
to
alternator
(M16
nut)
.......
60
Nm
(44
ft-Ib)

Voltage
regulator,
removing
and
installing

1
.
Disconnect
negative
(-)
cable
from
battery
.

NOTE-



2
.
Remove
alternator
as
described
earlier
.

The
radiator
cooling
fan
nut
(32
mm
wrench)has
left-
hand
threads
.



3
.
Remove
cooling
duct
from
rear
of
alternator
.
See
Fig
.
6
.

Alternator

.
.g-



p~
J

-..
.

Fig
.
6
.



Alternator
assemblyand
related
parts
.

Cooling
duct

0012524

4
.
Remove
voltage
regulator
mounting
screws
and
re-

move
regulator
from
alternator
.

5
.
Installation
is
reverse
of
removal
.
Clean
brush
contact

surfaces
in
alternator
and
check
brush
length
asde-

scribed
later
.

GENERAL
..
.
......
.
.
.
.....
.
...
.
.
.
.
.
.
.
.
200-1

Manual
Transmission
.
.
.....
.
.
.
.'
.
.
.
.
.
.
.
.
200-1

Automatic
Transmission
.........
.
.
.
.
.
.
.
.
200-1

Transmission
ID
Codes
..........
.
.
.
.
.
.
.
.
200-2

GENERAL

E36
models
areequipped
with
a
longitudinal
drivetrain
.
The

transmission
is
bolted
directly
to
the
rear
of
the
engine
.
A

driveshaft
connects
the
output
shaft
of
thetransmission
to
the

final
drive
.
The
final
drive
is
mounted
lo
the
rear
suspension

and
the
body
.
Individual
drive
axles
with
integrated
constant

velocity
joints
transfer
rotational
power
to
the
rear
wheels
.

Manual
Transmission

Due
to
different
power
characteristics
and
performance
re-

quirements,
four
different
manual
transmissions
are
used
in

the
models
coveredby
this
manual
.
Manual
transmission
ap-

plications
are
given
in
Table
a
.

TRANSMISSION-GENERAL
200-1

200
Transmission-General

TABLES

a
.
Manual
Transmission
Applications
..
...........
200-1
b
.
Automatic
Transmission
Applications
...........
200-1

Fig
.
1
.



ZF-manufacturedmanual
transmission
.

For
transmission
gear
ratio
information
and
repair
informa-

tion,
see
230
Manual
Transmission
.



Automatic
Transmission

E36
carswith
standard
transmission
use
a
single-disc
clutch
with
dual-mass
flywheel
.
For
further
information,
see
210
Clutch
.

Table
a
.
Manual
Transmission
Applications

Model
Year
Engine
Transmission
318ifisfC



1992-1995



M42



Getrag
S5D
200
G'

1996-1998



M44



Getrag
S5D
250
G

323is/iC



1998



M52



Getrag
S5D
250
G

325ifsriC



1992-1995



M50



Getrag
S5D
250
G

3281/isfC



1996-1998



M52



ZF
S5D320
Z

M3



1995



S50US



ZF
S5D310
Z

1996-1998



S52US



ZF
S5D320
Z

'The
1992
M42
engine
may
be
fitted
witheither
the
Getrag
SSD
200
G
trans-
mission
or
S5D
250
Getrag
.
The
S5D
200G
was
discontinued
in
production
in
as
of
9/92
.
Thistransmission
is
interchangeable
with
Getrag
S5D
250
G
.

Four
different
automatic
transmissions
are
used,
depend-

ing
on
model
and
model
year
and/or
production
date
.
All
of
the

automatic
transmissions
are
electrohydraulically
controlled

with
either
four
or
five
forward
speeds
.
Automatic
transmis-

sion
applications
are
given
in
Table
b
.

For
automatic
transmission
repair
information,
see
240Au-

tomatic
Transmission
.

Table
b
.
Automatic
Transmission
Applications

Model
1
Year
1
Engine
1
Transmission

318i1is/1C



1992-1995
~
M42
323isfiC



1998



M52



A4S
310
R
3251/is/1C
1992-1995
M50

3181/isfC



11996-1998



M44



A4S
270
R
328i/is/1C
1996-1998
M52

M3



1996-1998



S50US



I
A5S
310
Z
S52US

GENERAL

GENERAL
..
.
.
.
.
.
.
.
.
.
.
.
.
.
......
.
......
210-1



CLUTCH
MECHANICAL
.
.
.
.
.
...
.
.....
.
.
210-3

CLUTCH
HYDRAULICS
.
.
.
.............
210-1



Clutch,
removing
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
...
.
.
.
.
210-4

Clutch,inspecting
and
installing
.
.
.
.
.
.
.
.
.
.
.
.210-5Clutch
hydraulic
system,



Transmission
pilot
bearing,replacing
.
.
.
.
...
210-6
bleeding
and
flushing
.
.
.
.
.
.......
.
.....
210-2

Clutch
master
cylinder,
replacing
..
.
.
.
.
.
...
210-2



Table

Clutch
slave
cylinder,
replacing
...
.
.
.
.
.
.
.
.
210-3



a
.
Clutch
Disc
Diameter
.............
..
..
.
......
210-3

GENERAL



CLUTCH
HYDRAULICS

This
repair
group
covers
replacement
of
the
clutch
mechan-



The
Clutch
is
hydraulically
actuated
by
the
master
and
slave
¡cal
and
hydraulic
components
.
Special
tools
may
be
required



cylinders
.
Clutch
disc
wear
is
automatically
taken
upby
the
for
some
of
the
procedures
.
Read
the
procedure
through
be-



pushrod
travelof
the
slave
cylinder,
making
periodic
adjust-fore
beginning
a
job
.



ments
unnecessary
.

NOTE-

See200
Transmission-General
for
transmission
applicatíon
information
.

The
major
components
of
the
clutch
system
are
shown
in

Fig
.
1
.

Engine



Pressure
plate

flywheel,,
assembly

Clutch

Flywheel
bolt

Pressure
plate
release
lever



Release
lever

Fig
.
1
.



Clutch
assembly
and
hydraufcs
.

210
Clutch

Release
bearing

Pushrod

A
soft
or
spongy
feel
to
the
clutchpedal,
long
pedal
free-
play,
or
grinding
noises
from
thegears
while
shifting
can
all
in-
dicate
problems
with
the
Clutch
hydraulics
.
In
these
circum-
stances
it
is
best
to
start
with
a
clutch
fluid
flush,
followed,
if

necessary,
byreplacement
of
the
hydraulic
parts
.

From
brake
fluid
reservoir

CLUTCH
210-1

0

0

Transmission
inputshaft

Clutch
master
cylinder

Bulkhead

Slave
cylinder
6535

CLUTCH
HYDRAULICS

210-2
CLUTCH

Clutch
hydraulic
system,

bleeding
and
flushing

If
the
clutch/brake
fluid
is
murky
or
muddy,
or
has
not
been

changed
within
the
last
two
years,
the
system
should
be

flushed
.
Flushing
the
old
fluid
from
the
clutch
lines
is
done
us-

ing
a
brake
system
pressure
bleeder
.

1
.
Remove
brake
fluíd
reservoir
cap
.
Usinga
clean
sy-

ringe,
remove
brake
fluid
from
reservoir
.
Refill
reservoir

with
clean
fluid
.

2
.
Attach
pressure
brake
bleeder
to
fluid
reservoír
.

CA
UTION-

Do
not
exceed
2
bar
(29
psi)
pressure
at
the
fluid
reservoir
when
bleeding
or
flushing
the
hydraulic
system
.

3
.
Connect
a
length
of
hose
from
clutch
slave
cylinder

bleeder
valve
lo
a
container
.
See
Fig
.
2
.

0012003
Fig
.
2
.



Clutch
slave
cylinder
bleeder
valve
on
left
side
of
transmission
(arrow)
.

4
.
Open
bleeder
valve
and
allow
brake
fluid
to
expel
until
clean
fluid
comes
out
free
of
air
bubbles
.

5
.
Close
bleeder
valve
and
disconnect
pressure
bleeding
equipment
from
fluid
reservoir
.
Hose
on
bleeder
valve
remainsconnected
.

6
.
Slowly
operate
clutch
pedal
about10
times
.
Fill
reser-
voir
with
clean
fluid
asnecessary
.

7
.
Unbolt
slavecylinder
from
transmission
.

8
.
Position
slave
cylinder
so
that
bleeder
valve
is
facing
up
(highest
point)
.

CLUTCH
HYDRAULICS

9
.
Open
bleeder
valve
and
slowly
push
slave
cylinder

pushrod
al¡
the
way
in
.
Close
bleeder
valve
and
slowly

release
pushrod
.
Repeat
procedure
until
fluid
runs
out

clear
and
without
bubbles
.

10
.
Disconnect
bleeder
hose
.
Instan
slavecylinder
lo
trans-

mission
.
Add
cleanbrake
fluid
to
reservoir
as
neces-

sary
.
Check
clutch
operation
.

Tightening
Torques

"
Clutch
slave
cylinder
to
transmission
................
..
22
Nm
(17
ft
lb)

Clutch
master
cylinder,
replacing

The
clutch
master
cylinder
is
mounted
to
the
pedal
assem-

bly,
directly
above
the
clutch
pedal
.
1
.
Disconnect
negative
(-)
cable
from
battery
.

CAUTION-

Prior
to
disconnectiog
the
battery,
read
the
battery
disconnection
cautionsgiven
at
the
front
of
this
manual
on
page
viii
.

2
.
Remove
brake
fluid
reservoir
cap
.
Usinga
clean
sy-

ringe,
remove
brake
fluid
from
reservoir
.

CA
UTION-

Brake
fluid
is
poisonous,
highly
corrosive
and
dan-gerous
to
the
environment
.
Wear
safety
glasses
and
rubbergloves
when
working
with
brake
fluid
.
Do
notsiphonbrake
fluid
with
your
mouth
.
Imme-
diately
clean
away
any
fluid
spilled
on
painted
sur-
faces
and
wash
with
water,
asbrake
fluid
will
remove
point
.

3
.
Disconnect
fluid
supply
hose
from
master
cylinder
.

Placea
pan
under
hose
to
catch
any
excess
fluid
.

4
.
Working
in
engine
compartment,
disconnect
fluid
line
fitting
frommaster
cylinder
.

5
.
Working
in
passenger
compartment,
remove
lower
in-
strument
panel
trim
above
pedal
cluster
.

6
.
Disconnect
clutch
pedal
from
clutch
master
cylinder
push
rod
by
removing
clevis
pin
locking
clip
and
slide
out
clevis
pin
.

7
.
Remove
master
cylinder
mounting
bolts
.
See
Fig
.
3
.

8
.
Installation
is
reverse
of
removal
.
Fill
fluid
reservoir
with
clean
fluid
.
Bleed
clutch
hydraulics
as
described
earlier
.

Connect
negative
cable
to
battery
last
.