Clutch replacement: Citroen C2 MA5 (ET3J4, TU1JP, TU3JP, TU5JP4, …)

🧭 Before you start

Fits: platform codes 1.1, 8V, |, 1.4, 16V, 1.6, VTS

• Opens: clutch fluid

Don't miss

• Use the special tool to counterhold

🔧 Engine codes this applies to

📋 Procedure

Preparation and removal

1. - Bleeding the hydraulic circuit
2. All vehicles:
3. Renew the gaskets
4. Disconnect the battery
5. Raise and support the vehicle with the front wheels suspended

6. Remove the left wheel arch liner
7. Exhaust pipe support
8. Pendulum support bolts
9. Type 1:
10. Remove the clip
11. Slide the tube in the direction shown
12. Drive shaft seal fitting tool(s)
13. Remove the clip
14. Slide the tube in the direction shown
15. Type 2:
16. Remove the cover
17. Connect a transparent pipe to the bleed hole
18. Press and hold the clutch pedal
19. Open the bleed screw
20. Move as shown
21. Allow excess fluid to drain off
22. Close the bleed screw
23. Release the clutch pedal
24. Repeat the procedure 20 times
25. Until no bubbles come out
26. Top up the clutch fluid if necessary
27. Disconnect the hose connected to the air-bleed valve
28. Type 3:
29. Remove the cover
30. Connect a transparent pipe to the bleed hole
31. Press and hold the clutch pedal
32. Open the bleed screw
33. Allow excess fluid to drain off
34. Close the bleed screw
35. Release the clutch pedal
36. Repeat the procedure 20 times
37. Until no bubbles come out
38. Top up the clutch fluid if necessary
39. Disconnect the hose connected to the air-bleed valve
40. Remove the drive shaft nuts
41. Use the special tool to counterhold
42. Disconnect the track rod ends
43. Note: Mark the position
44. Use the special tools
45. Disconnect the drive shafts from the wheel bearing housings
46. Remove the drive shafts from the differential
47. Plug the gearbox drive shaft hole
48. Remove the battery cover
49. Remove the battery
50. Remove the air filter housing
51. Remove the engine control unit with bracket
52. Remove the air inlet resonator from the throttle body
53. Remove the power steering control unit
54. Remove the battery tray
55. Disconnect the reversing light switch
56. Disconnect the earth cable from the gearbox
57. Disconnect the electrical wiring from the gearbox
58. Disconnect the gear-shift mechanism from the gearbox
59. Unclip the clutch hydraulic line
60. Remove the clutch slave cylinder
61. Disconnect the connector
62. Remove the bolts shown
63. Separate the exhaust system at the double clamp
64. Remove the torque rod
65. Remove the pendulum support
66. Remove the bolts shown
67. Remove the remaining engine/gearbox attaching bolts
68. Fit the special tool to support the engine
69. Remove the gearbox support
70. Lower the gearbox slightly
71. Remove the gearbox

Installation and checks

72. Top up the oil in the gearbox
73. Top up the clutch fluid if necessary
74. Ball joint splitting tool:
75. Move the hydraulic line back to close the bleed hole when clutch fluid flows out without bubbles
76. Top up the clutch fluid if necessary
77. Press and hold the clutch pedal
78. Fit the clip
79. Slide the tube in the direction shown
80. Remove the clip
81. Release the clutch pedal
82. Repeat the procedure 20 times
83. Until no bubbles come out
84. Top up the clutch fluid if necessary
85. Disconnect the hose connected to the air-bleed valve
86. Refit the cover
87. Refit the cover
88. Press and hold the clutch pedal
89. Press and hold the clutch pedal
90. Measure the distance:
91. Release the clutch pedal
92. Bleed the hydraulic clutch system

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