Clutch Master Cylinder: Service and Repair

Clutch master cylinder, removing and installing, 02M/02Y, 5 & 6 Speed M/T, AWD

Special tools, testers and auxiliary items required





^ Pliers T10005





Removing
- Remove left front cover - arrows -.

Vehicles with 4 cylinders Engine:





- Remove air guide hose from Throttle Valve Control Module J338, to do so remove hose clamp - 4 -.
- Disconnect electrical harness connector at Mass Air Flow (MAF) Sensor G70 - 1 -.
- Disconnect hose - 5 - from air filter housing if installed.
- Remove bolts - 2 - and - 3 -.
- Remove air filter housing.

Vehicles with 6 cylinders Engine:





- Disconnect air guide hose - 2 - at Throttle Valve Control Module J338.
- Disconnect electrical harness connector at Mass Air Flow (MAF) Sensor G70 - item 3 -.
- Remove bolts - 1 - and - 4 -.
- Expose electrical wire - arrow -.
- Remove air filter housing.

All:





- Remove supply hose - A - from brake fluid reservoir and seal.
- Remove clip - B - for hose/line assembly.
- Disconnect hose/line assembly - C - from clutch master cylinder and seal.
- Remove driver side storage compartment.
- Remove clutch pedal switch.





- To disengage clutch master cylinder operating rod from clutch pedal, pull pedal slightly into passenger compartment and press both sides of mount inside using pliers T10005 - arrows -.





- Remove bolts - arrows 1 - and connecting bracket - A -.
- Remove nuts - arrows 2 - and remove mounting bracket - B -.





- Rotate stop - A - for clutch pedal in direction of - arrow - and remove.





- Press clutch master cylinder first to stop in direction of - arrow 1 -.
^ It must not be covered in the upper area of bearing for over-center spring - arrow 2 -.
- Then swing clutch master cylinder in direction of - arrow 3 - out of mounting bracket.

Installing
Installation is performed in reverse order of removal. Note the following:





^ Retainer - A - must be located on operating rod - B - of clutch master cylinder.
- Press clutch pedal in direction of - arrow - to engage, ensure correct engaging while doing so.





- Insert stop - A - for clutch pedal.
^ Installed position: The holder - arrow - points to clutch master cylinder - B -.
- Install clutch pedal switch.
- Bleed clutch system.