Removal and Replacement

CLUTCH MASTER CYLINDER


Removal and Installation


CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately and wash the affected area with water.

REMOVAL
1. Drain clutch fluid. Draining.
2. Remove brake master cylinder cover. Removal And Installation.
3. Remove brake booster pressure sensor. Removal And Installation.





4. Remove mounting bolts ( ) and then remove reservoir tank assembly from the vehicle.

Arrow: Vehicle Front

5. Remove hose and clips from reservoir tank and master cylinder.
6. Remove reservoir tank mounting bolts and washers and then remove bracket from reservoir tank.
7. Remove ABS actuator and electric unit (control unit). Refer to
Removal And Installation VDC/TCS/ABS.
8. Remove clutch tube from master cylinder, using a flare nut wrench.
9. Remove snap pin and clevis pin from clevis and then separate clevis from clutch pedal.





10. Remove master cylinder mounting nuts and then remove packing (1) and master cylinder assembly (2) from the vehicle.

Arrow: Vehicle Front

CAUTION:
Never damage packing, brake booster, and dash lower.

INSTALLATION





1. Install packing (1) and master cylinder assembly (2) to the vehicle.

Arrow: Vehicle Front

CAUTION:
- Never damage packing, brake booster, and dash lower.





- Be careful with the orientation of packing. The figure is the view from the vehicle forward.
2. Tighten master cylinder mounting nuts to the specified torque.
3. Connect clutch tube to master cylinder and then temporarily tighten clutch tube flare nut, using a flare nut wrench.
4. Set clevis to clutch pedal.
5. Apply recommended grease to clevis pin and then install clevis pin to clevis.
6. Install snap pin to clevis pin.
7. Tighten clutch tube flare nut to the specified torque, using a flare nut torque wrench [Commercial service tool]. Exploded View [1][2]Diagrams,
"Exploded View".

CAUTION:
Never damage flare nut and clutch tube.
8. Install ABS actuator and electric unit (control unit). Removal And Installation VDC/TCS/ABS.
9. Install washers to reservoir tank mounting bolts.
10. Install bracket to reservoir tank and then tighten reservoir tank mounting bolts to the specified torque.





11. Install hose (1) and clips to reservoir tank (2) and master cylinder (3).

Arrow: Painted Mark


CAUTION:
Set hose with painted mark facing upward.





12. Install reservoir tank assembly to the vehicle and then tighten mounting bolts ( ) to the specified torque.

Arrow: Vehicle Front

13. Install brake booster pressure sensor. Removal And Installation.
14. Install brake master cylinder cover. Removal And Installation.
15. Fill with clutch fluid. Refilling.