Clutch Master Cylinder: Service and Repair
CLUTCH MASTER CYLINDERComponents:
REMOVAL
1. PRECAUTION
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment.
3. REMOVE FRONT DOOR SCUFF PLATE LH (w/o Illumination)
4. REMOVE FRONT DOOR SCUFF PLATE LH (w/ Illumination)
5. REMOVE FRONT DOOR OPENING TRIM COVER LH
6. REMOVE SIDE INSTRUMENT PANEL LH
7. REMOVE NO.1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY
8. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY
9. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY
10. DISCONNECT WIRE HARNESS
a) Disconnect the 3 connectors and clamp.
11. DISCONNECT CLUTCH RESERVOIR TUBE
a) Disconnect the clutch reservoir tube.
HINT: Use a container to catch the fluid.
12. DISCONNECT CLUTCH LINE
a) Using SST, disconnect the clutch line from the clutch master cylinder.
SST 09023-00101
HINT: Use a container to catch the fluid.
13. REMOVE CLUTCH PEDAL SUPPORT SUB-ASSEMBLY
a) Remove the 2 nuts, bolt and clutch pedal support.
14. REMOVE CLUTCH START SWITCH ASSEMBLY
a) Remove the nut and clutch start switch assembly from the clutch pedal support.
15. REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS PIN
a) Remove the clip and pin.
16. REMOVE CLUTCH MASTER CYLINDER ASSEMBLY
a) Remove the clutch reservoir tube.
b) Remove the 2 bolts and clutch master cylinder assembly.
INSTALLATION
1. INSTALL CLUTCH MASTER CYLINDER ASSEMBLY
a) Install the clutch master cylinder assembly with the 2 bolts.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
b) Connect the clutch reservoir tube.
2. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS PIN
a) Apply MP grease to the contact surface of the pin and a clevis bushing.
b) Connect the clevis to the clutch pedal with the pin.
HINT: Install the pin from the left side of the vehicle.
c) Install the new clip to the pin.
3. INSTALL CLUTCH START SWITCH ASSEMBLY
a) Install the clutch start switch assembly with the nut.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
4. INSTALL CLUTCH PEDAL SUPPORT SUB-ASSEMBLY
a) Install the clutch pedal support with the 2 nuts and bolt.
Torque: Bolt 24 Nm (242 kgf-cm, 17 ft. lbs.)
Nut 20 Nm (202 kgf-cm, 15 ft. lbs.)
5. CONNECT CLUTCH LINE
a) Using SST, connect the clutch line.
SST 09023-00101
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
NOTICE: Use a torque wrench with a fulcrum length of 300 mm (11.81 inch).
6. CONNECT CLUTCH RESERVOIR TUBE
a) Connect the clutch reservoir tube.
7. INSTALL WIRE HARNESS
a) Connect the 3 connectors and clamp.
8. BLEED CLUTCH LINE
a) Fill the brake reservoir with the brake fluid and bleed the clutch system.
Torque: 11 Nm (112 kgf-cm, 8 ft. lbs.)
9. CHECK FOR BRAKE FLUID LEAKAGE
HINT: Check for leakage in the clutch system.
10. INSPECT AND ADJUST CLUTCH PEDAL HEIGHT
11. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY
12. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY
13. INSTALL NO.1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY
14. INSTALL SIDE INSTRUMENT PANEL LH
15. INSTALL FRONT DOOR OPENING TRIM COVER LH
16. INSTALL FRONT DOOR SCUFF PLATE LH (w/o Illumination)
17. INSTALL FRONT DOOR SCUFF PLATE LH (w/Illumination)
18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
19. INSPECT BRAKE FLUID LEVEL IN RESERVOIR
20. PERFORM INITIALIZATION
Some systems need initialization after reconnecting the negative battery terminal.
21. INSPECT SRS WARNING LIGHT