Removal and installation the clutch master cylinder (Opel Astra G)

Removal

1. To ensure adequate access, remove the relay c mounting block from the top of the hydraulic anti-lock braking System (ABS) modulator. Remove the relay holder support bracket and move it to the side.

2. Thoroughly wipe the outside surface of the master cylinder and place a rag underneath it to collect any spilled hydraulic fluid.

3. Use a clamp to clamp the feed hose connecting the reservoir to the master cylinder.

The hose should be pinched at a distance of about 5 cm from the cut of the end stretched onto the cylinder nipple. Immediately plug the hole in the tank to prevent dirt from getting into the tract.

4. Remove the retainer, slide the clamp and disconnect the hydraulic tube from the master cylinder - to minimize the loss of hydraulic fluid, wrap the union with a rag. Immediately plug the open ends of the line and union to prevent dirt from getting into the system.

To avoid damage to the paintwork, do not allow hydraulic fluid to come into contact with the painted surfaces of the body panels! Remove the sealing ring from the nipple connector - it must be replaced during assembly.

5. In the passenger compartment, disconnect the return spring from the clutch pedal. Remove the lower left section of the instrument panel trim (see Chapter Body), release the lock, remove the pin and disconnect the split pin of the hydraulic master cylinder pusher from the clutch pedal.

6. In the same place, remove the two nuts securing the master cylinder to the engine compartment bulkhead/pedal support bracket. Go to the engine compartment and remove the master cylinder assembly complete with sealing gasket.

Installation

Prepare a new sealing ring for the hydraulic tube master cylinder connection nipple.

1. Make sure that the mating surfaces of the clutch master cylinder assembly and the engine compartment bulkhead are absolutely clean and dry. Install the sealing gasket in place.

2. Place the master cylinder in its regular place and secure it with bolts, hand tightening the nuts.

3. Restore the original connection of the hydraulic lines - do not forget to replace the sealing elements and ensure that the nipple connections are securely fastened.

When connecting the hydraulic tube to the master cylinder, the nipple connector should make a characteristic click.

4. Tighten the cylinder mounting nuts to the required torque.

5. Connect the cylinder pushrod to the clutch pedal and secure the split pin with a new pin - lubricate the pin with multi-purpose grease before installing. Connect the return spring to the pedal, then reinstall the lower section of the instrument panel trim.

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6. Reinstall the relay holder bracket and mounting block.

7. Finally, "pump" the hydraulic system to remove air locks (see Bleeding air from the hydraulic circuit of the clutch release drive).