Repair Manual – Page 22

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Here’s a detailed guide on how to replace the clutch master cylinder on a Mercedes Benz E-Class AMG W213 using OEM parts. This process requires mechanical knowledge and certain tools. Always ensure safety measures are taken during the process.

### Tools and Materials Needed:

– **Wrenches and Sockets**:
– **10mm, 13mm, and 15mm socket** – For removing bolts and nuts securing the components.
– **Ratchet and extensions** – To reach bolts in tight spaces.
– **Open-end wrench** – For areas that a socket cannot access.

– **Pliers**:
– **Needle-nose pliers** – For removing clamps or hoses.

– **Screwdrivers**:
– **Flat-head and Phillips screwdrivers** – For prying off clips and screws.

– **Brake Bleeder Kit**:
– **One-man brake bleeder** – To bleed the clutch system after the replacement.

– **Fluid Container**:
– To catch any leaking brake fluid during the process.

– **New Clutch Master Cylinder**:
– Ensure it’s an OEM part designed for the W213 model.

– **Brake Fluid**:
– Recommended type (usually DOT 4) for refilling the reservoir after replacement.

– **Shop Towels**:
– For cleaning up spills and maintaining a clean workspace.

– **Safety Glasses and Gloves**:
– To protect your eyes and hands while working.

### Replacement Procedure:

– **Preparation**:
– Park the vehicle on a level surface and engage the parking brake.
– Disconnect the negative battery terminal to prevent any electrical short circuits.

– **Accessing the Clutch Master Cylinder**:
– Remove any necessary panels or covers to access the pedal assembly.
– Depending on the configuration, you may need to remove the driver’s side footwell panel.

– **Disconnecting the Clutch Master Cylinder**:
– Locate the clutch master cylinder, typically attached near the brake pedal.
– Disconnect the clutch fluid line from the master cylinder using the appropriate wrench. Have a fluid container ready to catch any leaking fluid.
– Remove any electrical connectors, if applicable, from the master cylinder.

– **Removing the Master Cylinder**:
– Unscrew the bolts securing the master cylinder to the pedal assembly using your socket set.
– Carefully slide the master cylinder out of its mounting area. Be cautious of any remaining fluid.

– **Installing the New Clutch Master Cylinder**:
– Position the new master cylinder in place, ensuring it aligns with any mounting points.
– Secure it with bolts and tighten them to the manufacturer’s specifications.
– Reconnect the clutch fluid line and any electrical connectors that were removed.

– **Refilling the Clutch Fluid**:
– Locate the clutch fluid reservoir (often shared with the brake fluid reservoir).
– Fill it with the recommended brake fluid to the appropriate level.

– **Bleeding the Clutch System**:
– Use a brake bleeder kit to remove air from the system:
– Have an assistant press the clutch pedal while you open the bleeder valve before the pedal is released to prevent air from re-entering.
– Repeat until no air bubbles are visible in the fluid.
– Check the fluid level frequently and top it off as needed during the bleeding process.

– **Final Checks**:
– Reinstall any panels or covers that were removed during the process.
– Reconnect the negative battery terminal.
– Start the vehicle and test the clutch pedal for proper operation.
– Ensure there are no leaks around the master cylinder and fluid lines.

– **Cleanup**:
– Dispose of any used brake fluid and materials in accordance with local regulations.
– Clean any spills with shop towels.

### Important Notes:
– Always consult the vehicle’s service manual for specific torque specifications and additional details that may pertain to your particular model year.
– If you’re unsure about any step, consider seeking professional assistance to avoid damaging components or voiding warranties.
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