Opel Frontera UE. Manual - part 452

CLUTCH

7C–27

Master Cylinder

208RX003

Legend

(1) Reservoir Cap
(2) Inner Cap
(3) Seal
(4) Reservoir

(5) Clip
(6) Body Sub Assembly
(7) Gasket
(8) Nut
(9) Yoke

Disassembly

1. Disassemble reservoir cap (1), inner cap (2), seal (3),

clip (5), and reservoir (4).

2. Disassembly gasket (7), yoke (9), nut (8) and body

sub assembly.

Inspection and Repair

Make the necessary adjustments, repair, and part
replacements if excessive wear or damage is discovered
during inspection.

Reassembly

To reassemble, follow the disassembly steps in the
reverse order.

7C–28

CLUTCH

Slave Cylinder

Disassembled View

206RS002

Legend

(1) Push Rod
(2) Boot

(3) Piston and Piston Cup
(4) Spring
(5) Cylinder Body

Disassembly

1. Disassemble boot (1), push rod (2), piston and piston

cup (3), and spring (4) from cylinder body (5).

Inspection and Repair

Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is discovered
during inspection.

Cylinder Body

1. Clean the cylinder body.
2. Check the fluid return port for restrictions and clean it

if necessary.

206RS003

CLUTCH

7C–29

Piston and Piston Cup

1. Visually inspect the disassembled piston and piston

cup for excessive wear and damage.

206RS004

Replace the inner parts with new parts if necessary.

2. Measure the clearance between slave cylinder wall

and piston.

206RS005

If the measured value exceeds the specified limit, the
slave cylinder assembly must be replaced.

Standard: 0.07 mm (0.0028 in)
Limit: 0.15 mm (0.0059 in)

Reassembly

To reassemble, follow the disassembly steps in the
reverse order, noting the following points:

Piston Assembly

1. Before installing the parts, apply a thin coat of rubber

grease.

2. Install cup in groove in piston with the lip turned to the

front of cylinder.   Use care so as not to scratch the
cylinder.

206RS006

7C–30

CLUTCH

Damper Cylinder

Disassembled View

205RW005

Legend

(1) Cylinder Body
(2) Spring
(3) Piston Assembly

(4) Spacer
(5) Damper Rubber
(6) Cover and Gasket

Disassembly

1. Disassembly cover and gasket (6).
2. Disassembly damper rubber (5).
3. Disassembly spacer (4).
4. Disassembly piston assembly (3).
5. Disassembly spring (2).
6. Disassembly cylinder body (1).

Inspection and Repair

Check damper rubber and piston cup for cracks,
deformation or damage.
Replace the damper cylinder assembly if necessary.

Reassembly

To assemble, follow the disassembly steps in the reverse
order.