Page 9 of 22
30-8
7 -
Bracket for harness connector
8 -
Clutch Pedal Position (CPP) switch -F194-
Adjusting Page 30
-9
9 -
Clip
10 -
Screw and washer assembly
8 Nm (71 in. lb)
11 -
Mounting plate
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Page 10 of 22
30-9
Clutch Pedal Position (CPP) switch -
F194-, adjusting
- Loosen two bolts slightly (arrows).
- Have second technician fully depress clutch pedal up to stop.
- Place feeler gauge -A- with specific dimension -a- 3.2 mm (0.126 in.)
between operating surface of clutch pedal and switch cam.
Thickness -a- of feeler gauge: 3.2 mm (0.126 in.)
- Move switch -B- toward gauge -A- until stop, and tighten two mounting
bolts (arrows) to 8 Nm (71 in. lb).
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Page 11 of 22
30-10
Clutch hydraulic system, servicing
1 -
Brake fluid reservoir
2 -
Supply hose
For clutch master cylinder
3 -
Hose/line assembly With threaded connections on clutch
master cylinder and clutch slave cylinder
4 -
Line fitting 15 Nm (11 ft lb)
5 -
Mounting bracket
6 -
Clutch pedal Removing and installing Page 30
-5
7 -
Socket-head bolt
20 Nm (15 ft lb)
8 -
9Pin and locking plate
10 -
Clutch master cylinder Removing and installing Page 30
-13
11 -
Transmission
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Page 12 of 22
30-11
CAUTION!
Do not operate after the clutch pedal has been
removed.
Brake fluid must not be allowed to get onto the
transmission.
CAUTION!
Fill the brake fluid reservoir up to the "max"
marking with brake fluid before bleeding the
hydraulic clutch system with the brake bleeder. 12 -
Clutch slave cylinder
Coat plunger of clutch slave cylinder with
copper grease e.g. Z381 351 TE
For clutch slave cylinders with plastic support
ring, lightly lubricate outer surface of ring before
installing
When installing, push in until bolt can be
installed
13 -
Bleeder valve
4.5 Nm (40 in. lb)Observe all CAUTIONS, WARNINGS,
Notes and procedures when bleeding
Page 30
-17
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Page 13 of 22
30-12
14 -
Bracket
Mounted to transmission
15 -
Bolt
8DVA 000 504 bolt:25 Nm (18 ft lb)
8DVA 000 505 socket-head bolt:20 Nm (15 ft lb)
16 -
Nut 2 Nm (18 in. lb)
17 -
Seal
18 -
Seal Must not be removed
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Page 14 of 22
30-13
Clutch master cylinder, removing and
installing
Special tools and equipment
3094 hose clamp
Removing
CAUTION!
Before working on the electrical system:
Determine the correct coding for the anti-
theft radio.
Switch the ignition off (also applies when
connecting the battery). Failure to do so may
damage the Engine Control Module (ECM).
Disconnect the battery Ground (GND)
strap.
To remove E-box from plenum chamber:
- Remove bolts (arrows) and remove cover.
- Remove Engine Control Module (ECM); if necessary remove 8-pin
relay support Repair Manual, Electrical Equipment, Repair Group 97- Disconnect harness connectors at connector station.
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Page 15 of 22
- Remove engine wiring harness together with rubber grommet from
opening in E-box.
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Page 16 of 22
30-14
CAUTION! - Remove both nuts -A-
- Lift E-box out at rear of threaded bolt and remove from mounting point -
B-.
When carrying out the following steps, make sure that no brake
fluid escapes into the plenum chamber or onto the transmission
below. If this does occur, clean thoroughly. When working in the area of the footwell, make sure to protect the
carpeting from brake fluid which may run out.
- Clamp supply hose -A- from brake fluid reservoir using 3094 hose
clamp. Pull hose off clutch master cylinder and plug hose.
- Disconnect line -B- from clutch master cylinder and seal.
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