I am new to Alfa ownership and have a 156 and love the car but it has now developed a fault with the clutch master cylinder.
I plan on completing the change myself but cant find a how to on this or any information, i have seen examples for a TS model but not a JTD.
Would anyone be able to offer advice on the best steps to change this on my car?
You have posted in the 159 section, do you mean 156 or 159? Although I cant imagine they are much different, its a common failing part on the 159, darn german made parts!!
1. Allow yourself plent of room to fully open the drivers door and get a good torch, if your tall, prepare to get very uncomfortable and possibly even getting stuck in the footwell! The 159 replacement master includes the bulkhead connecting part, disconnect the pipes to this as you wont need to replace this bit and it will be a very complex job to fit it with that.
2. With a 10mm spanner and socket, get behind the clutch pedal and undo the 2 bolts and 2 nuts holding it in and gently prize off the plastic bit where its clipped to the pedal assembly. It should now be loose.
3. With a flat blade screw driver or pliers, pull out the metal clip holding the larger pipe to the cylinder. But dont remove the pipe, loosen the smaller return pipe.
4. Put something under the pipes to catch any leaking fluid, disconnect the pipes and then swap for the new one.
5. Connect up both pipes, dont forget the metal clip, make sure the pipes are push fitted correctly with the rubber seals in place (I swapped the seals for the new one from the bulkhead part) and not leaking. Bolt on the new cylinder assembly, I seem to remember the bolts/nuts will only go on a certain way around, check the pedal moves without catching them before fully tightening. Clip the pedal back on.
6. Under the bonnet, move the ecu out the way and loosen the slave cylinder bleed screw on the top of the gearbox, I think you will need a 17mm and 13mm for this, I cant remember. Bleed fluid by pumping the pedal until all air is removed, topping up the resorvoir making sure it doesnt go below min mark, when the pedal returns to the top. Job done.