Repair Procedures

Removal

1. Drain the brake fluid through the bleeding plug (A).




2. Remove the flexible hose (A) connected to brake reserve tank from the master cylinder.
3. Disconnect the clutch tube (B) from the master cylinder.




4. Disconnect the two ignition lock switch connectors.
5. Remove the clutch pedal mounting bolts (A-2ea) and the bracket mounting nuts (B-3ea).

Tightening torque :
(A,B) 16.7 - 25.5N.m (1.7 - 2.6kgf.m, 12.3 - 18.8lb-ft)




6. Remove the master cylinder mounting bolts (C-2ea).

Tightening torque :
(C) 11.8 - 14.7N.m (1.2 - 1.5kgf.m, 8.7 - 10.9lb-ft)




7. Disconnect the push rod from the master cylinder by removing the snap pin (A) and washer (B).
8. Remove the screws mounting the master cylinder (A) to the clutch pedal assembly (B).






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. Installation is reverse of removal.
2. Apply the specified grease to the clutch pedal and bushings.

Chassis grease: SAE J310a, NLGI No.1




3. Adjust the clutch pedal within the standard value, then secure by tightening the lock nut.

Standard value
Stroke (A) : 150 - 155mm (5.98 - 5.99in)
Free play (B) : 6 - 13 mm (0.24 - 0.51in)
Height (C) : 216mm (8.5in)




4. Refill the brake fluid.
5. Bleed the air in the clutch system.