Removal and installation the clutch master cylinder (BMW 5 Series E28)

Hydraulic fluid is poisonous. It also dissolves paint well. Be careful not to let the fluid come into contact with exposed skin or eyes. Keep a rag handy to soak up spills, and if it comes into contact with painted surfaces, rinse immediately with plenty of cold water.

Removal

1. Remove the brake fluid reservoir cap (for left-hand drive models) or a reservoir with hydraulic clutch fluid (for right-hand drive models) and use a syringe to remove fluid from the reservoir. On left-hand drive models, the fluid level should be below the brake line connection to the master cylinder.

2. On right-hand drive models, disconnect the hydraulic hose from the bottom of the reservoir and drain any remaining fluid.

3. Loosen the union nut and disconnect the clutch hydraulic line nipple from the front of the master cylinder.



4. Working under the instrument panel, remove the lower trim panel on the driver's side (see chapter Body). Loosen the bolt securing the clutch master cylinder push rod to the clutch pedal.

5. Loosen the two bolts that secure the master cylinder to the clutch pedal bracket, disconnect the hydraulic hose from the top of the master cylinder, and remove the master cylinder. Keep a rag handy to catch any spilled fluid.

Installation

1. Installation is basically the reverse of removal. Where applicable, ensure that the over-center helper spring is correctly seated in the guide. Remember to tighten the master cylinder mounting bolts to the specified torque. Tighten the clutch hydraulic line union nut securely.

2. Check the clutch pedal adjustment (see section Adjusting the clutch pedal). Where provided, also check the clutch switch adjustment (see section Checking the operation and replacing the clutch switch (where provided)).

3. Fill the reservoir with fresh hydraulic fluid and bleed the clutch system (see section Bleeding the hydraulic clutch system).