Clutch Master Cylinder: Service and Repair

Clutch Master Cylinder Replacement

NOTE:
- Use fender covers to avoid damaging painted surfaces.
- Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.





1. Remove the left rear engine compartment cover (A) and the left side engine compartment cover (B).
2. Remove the brake fluid from the clutch master cylinder reservoir with a syringe.
3. Make sure you have the anti-theft codes for the radio and the navigation system, then write down the customer's audio presets. Make sure the ignition switch is OFF.
Disconnect the negative cable from the battery first, then disconnect the positive cable.
Remove the battery.
4. Remove the air cleaner housing.





5. Remove the battery base.





6. Remove the under-hood fuse/relay box.
7. Remove the driver's dashboard under cover.





8. Pry out the lock pin (A), and pull the pedal pin (B) out of the yoke. Remove the master cylinder mounting nuts (C).





9. Remove the reservoir mounting bolt (A).
10. Disconnect the clutch line (B) from the bracket (C).
11. Remove the clutch line from the clamp (D).
12. Remove the clutch master cylinder (E).





13. Disconnect the reservoir hose (A), then remove the retaining clip (B), and remove the clutch line (C) from the clutch master cylinder (D). Plug the end of the reservoir hose and clutch line with a shop towel to prevent brake fluid from coming out.
14. Remove the O-ring (E) and clutch master cylinder seal (F) from the clutch master cylinder.
15. Install the clutch master cylinder in the reverse order of removal, and note these items:
- Apply brake assembly lube to the clutch line, and install a new O-ring.
- Tighten the master cylinder mounting nuts to 13 Nm (1.3 kgf-m, 9.4 ft. lbs.).
- Install the driver's dashboard lower cover.
- Install the under-hood fuse/relay box.
- Install the battery base.
- Install the air cleaner housing.
- Install the battery. Clean the battery posts and cable terminals with sandpaper. Connect the positive cable to the battery first, then connect the negative cable, and apply grease to prevent corrosion.
- Install the left rear engine compartment cover and the left side engine compartment cover.
- Enter the radio and navigation system anti-theft codes, then enter the customer's audio presets, and set the clock.





16. Make sure the hose clamps (A) are positioned on the master cylinder (B) and reservoir (C) as shown.





17. To prevent the retaining clip (A) from coming off, pry apart the tip of the retaining clip (B) with a screwdriver.
18. Bleed the clutch master hydraulic system.
19. Refill the brake fluid in the reservoir to the MAX (upper) level line.