Master cylinder — removal and installation (Opel Vectra B)

Removal

1. To improve access to the clutch master cylinder, remove the relay box from the top of the ABS modulator and move it to the side. If necessary, remove the brake booster.

2. To reduce the loss of brake fluid, remove the reservoir cap, place a sheet of plastic underneath and screw the cap securely onto the reservoir.

3. Loosen the clamp and remove the clutch master cylinder pipe from the feed tank, close the pipe and the feed tank nipple with plugs.

4. Inside the vehicle, unscrew the clips and remove the lower instrument panel trim on the driver's side to access the clutch pedal.

5. Release the mounting bracket and remove the hydraulic hose of the clutch slave cylinder from the working part of the master cylinder. Close the pipe and the channel of the clutch master cylinder with plugs.

6. In the vehicle's interior, remove the bracket and pull out the pin securing the master cylinder pushrod to the clutch pedal.

7. In the engine compartment, unscrew the nuts and remove the clutch master cylinder.

Installation

1. Check that the mating surface of the clutch master cylinder and the engine compartment bulkhead are clean and dry and install the gasket.

2. Install the clutch master cylinder so that the pushrod clamp aligns correctly with the clutch pedal. Tighten the clutch master cylinder mounting nuts.

3. Lubricate the pin with multi-purpose grease, align the pushrod clamp and clutch pedal and install the pin. Secure the pin with a locking clip.



4. Connect the clutch slave cylinder hose to the master cylinder and secure it with the mounting bracket.

5. Install the driver's side lower instrument panel trim.

6. Connect the master cylinder hose to the feed tank and secure with a clamp.

7. Bleed the hydraulic clutch system.