Repair Procedures

Removal

1. Remove the flexible hose (A) from the brake reserve tank.




2. After pulling out a clip, disconnect the clutch tube (B) from the master cylinder.
3. Disconnect the ignition lock switch connector (A).




4. Remove the push rod from the clutch pedal by removing the snap pin (A) and washer (B).




5. Remove the clutch pedal mounting nut (C-3ea).
6. Remove the clutch pedal bracket mounting nut (A-2ea).




7. Remove the clutch master cylinder from the clutch pedal assembly by rotating the clutch master cylinder 45 degree counter clockwise.

Inspection

1. Check the inside of the cylinder body for rust, pitting or scoring.
2. Check the piston cup for wear or distortion.
3. Check the piston for rust, pitting or scoring.
4. Check to make sure the clutch line tube is not clogged or restricted in any way.
5. Measure the master cylinder inside diameter and the piston outside diameter with a cylinder gauge micrometer.

NOTE:
Measure the inside diameter of the master cylinder at three places (bottom, middle, and top) in a perpendicular direction.

6. If the master cylinder-to-piston clearance exceeds the limit, replace the master cylinder and/or piston assembly.

Limit: 0.15 mm (0.006 in)

Installation

1. Install the clutch master cylinder to the clutch pedal assembly by rotating the clutch master cylinder 45 degree clockwise.
2. Install the clutch pedal bracket mounting nut (A-2ea).

Tightening torque :
13 - 16 Nm (1.3 - 1.6 kgf.m, 9.4 - 11.6 lb-ft)




3. Install the clutch pedal mounting nut (C-3ea).

Tightening torque :
13 - 16 Nm (1.3 - 1.6 kgf.m, 9.4 - 11.6 lb-ft)




4. Install the push rod to the clutch pedal by installing the snap pin (A) and washer (B).

Wheel bearing grease: SAE J310, NLGI No.2

5. Connect the ignition lock switch connector (A).




6. Install the flexible hose (A) to the brake reserve tank.




7. Connect the clutch tube (B) to the master cylinder and insert a clip.
8. Refill the brake fluid.
9. Bleed the air in the clutch system.