Attention! Elements of the hydraulic clutch control system (master cylinder, slave cylinder and connecting hoses) are a single unit and cannot be separated.
Attention! Access to the master cylinder is extremely limited. Peugeot recommends the use of a special tool (0216J). You can use a slotted box wrench to fit onto the hose.
Removing
1. Disconnect the negative battery terminal.
2. Inside the car, open the immobilizer cover and turn the fuse box cover lock by 90°. Disconnect the electrical connector from the block, unscrew the mounting screws and remove the lower panel from the driver's side.
3. Remove the air filter and air inlet.
4. Remove the master cylinder push rod ball joint from the clutch pedal.
5. In the engine compartment, remove the clutch master cylinder reservoir from the bulkhead.
6. Using the Peugeot special tool or a slotted ring wrench, rotate the master cylinder 90°clockwise and remove it from the bulkhead.
7. Remove the slave cylinder (1), by clicking on it (2), and in this position by turning 90°counterclockwise (3).
8. Remove the hydraulic hose from the mounting brackets and remove the entire assembly from the engine compartment.
Installation
Attention! On the new unit, the push rod of the slave cylinder is covered with a plastic shell that breaks when the clutch pedal is pressed for the first time. Do not attempt to remove this shell before installing the pushrod into the pedal, as during operation, the pusher may pop out of the pedal socket.
1. Depress the clutch pedal and hold it in this position.
2. Install the clutch master cylinder, matching the white mark on the cylinder with the corresponding white mark on the baffle. Using the Peugeot special tool, push in and turn the cylinder 90°counterclockwise until it locks into place.
3. Install the master cylinder reservoir on the bulkhead.
4. Lubricate the working end of the slave cylinder tappet with molybdenum disulphide grease and reinstall the slave cylinder by pushing in and turning it 90°clockwise in this position.
5. Secure the hydraulic hose with clips in the engine compartment.
6. Lubricate the master cylinder push rod ball joint, then lift the clutch pedal and connect to the push rod.
7. Slowly depress the clutch pedal and slowly manually lift it back. After 10 seconds, repeat this operation and check that the pedal returns normally to its original position.
8. Install the previously removed elements at the bottom of the panel and connect the battery.