Table of contents: Removal 🠇 Installation 🠇
Attention! Components of the hydraulic clutch control system (master cylinder, slave cylinder and connecting hoses) represent a single unit and cannot be separated.
Warning! Access to the master cylinder is extremely limited. Peugeot recommends the use of a special tool (0216J). You can use a slotted open-end spanner to fit it onto the hose.
Removal
1. Disconnect the negative battery terminal.
2. In the car, open the immobilizer cover and turn the fuse box cover lock 90°. Disconnect the electrical connector from the block, unscrew the mounting screws and remove the lower panel on the driver's side.
3. Remove the air filter and air intake duct.
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 open-end spanner, turn the master cylinder 90° clockwise and remove it from the bulkhead.
7. Remove the working cylinder (1) by pressing it (2) and in this position turning it 90° counterclockwise (3).
8. Remove the hydraulic hose from the mounting brackets and remove the entire assembly from the engine compartment.
Installation
Caution! On a new unit, the slave cylinder pusher is covered with a plastic shell, which breaks when the clutch pedal is pressed for the first time. Do not attempt to remove this shell before installing the pusher in the pedal, as the pusher may jump out of the pedal socket during operation.
1. Press the clutch pedal and hold it in this position.
2. Install the clutch master cylinder by aligning the white mark on the cylinder with the corresponding white mark on the bulkhead. Using the Peugeot special tool, press in and turn the cylinder 90° counterclockwise until it locks firmly into place.
3. Install the master cylinder reservoir on the bulkhead.
4. Lubricate the working end of the slave cylinder pushrod with molybdenum disulfide grease and install the slave cylinder into place by pushing it in and rotating it 90° clockwise in this position.
5. Secure the hydraulic hose with clamps in the engine compartment.
6. Lubricate the master cylinder pushrod ball joint, then lift the clutch pedal and connect it to the pushrod.
7. Slowly press the clutch pedal and slowly lift it back manually. After 10 seconds, repeat this operation and check that the pedal returns to its original position normally.
8. Install the previously removed elements into the bottom of the panel and connect the battery.