Clutch Master Cylinder: Service and Repair

CLUTCH MASTER CYLINDER REMOVAL/INSTALLATION [G66M-R]

CAUTION:
- Secure the steering wheel using tape or a cable to prevent the steering shaft from rotating after disconnecting the steering shaft. If the steering wheel rotates after the steering shaft and the steering gear and linkage are disconnected, the internal parts of the clock spring could be damaged.
- Do not allow clutch fluid get on a painted surface. Clutch fluid contains properties which can dissolve the paint. If clutch fluid gets on a painted surface, wash it off with water immediately and wipe the area off completely.

1. Disconnect the negative battery cable.

2. Remove the battery component. (ex: battery, battery tray) Removal and Replacement

3. Remove the starter interlock switch. Service and Repair

4. Remove the clutch pedal position switch. Service and Repair

5. Remove the Joint cover. Service and Repair

6. Disconnect the steering shaft from steering gear. Service and Repair

7. Disconnect the clutch pipe and hose No.1 from clutch master cylinder, and plug it to avoid clutch fluid leakage. Service and Repair

8. Disconnect the clutch reserve hose from clutch master cylinder, and plug it to avoid clutch fluid leakage. Service and Repair

9. Remove the clutch pedal installation nuts.






Tightening torque
- 19-25 Nm {2.0-2.5 kgf-m, 15-18 ft-lbf}

10. Remove the clutch master cylinder.
a. Disconnect the clutch master cylinder (rubber) from the body.

b. Rotate the clutch master cylinder in the direction of the arrow shown in the figure to disconnect the clutch master cylinder (body) and clutch pedal.






c. Disengage the tabs of the push rod and remove the clutch master cylinder using a flathead screwdriver.






11. Install the clutch master cylinder.
a. Insert the clutch master cylinder into the installation hole of the body.

b. Insert the stud bolt into the installation hole of the clutch pedal.






c. Engage the tabs of the push rod with the clutch pedal as shown in the figure.






d. Rotate the clutch master cylinder in the direction shown until it stops.






e. Install the clutch master cylinder (rubber) to the body.

12. Install in the reverse order of removal.

13. Bleed the air from the clutch system. Service and Repair

14. Fully depress the clutch pedal, and verify that the engine starts.