Clutch Master Cylinder: Service and Repair

Master Cylinder

REMOVAL
1. Thoroughly drain the brake fluid from reservoir tank.
2. Remove the snap pin, clevis pin and separate the push rod of master cylinder from clutch pedal.





3. Remove the air intake chamber (Non-turbo model).
4. Remove the intercooler (Turbo model).
5. Disconnect the clutch pipe from master cylinder.
6. Remove the master cylinder and reservoir tank as a unit.

CAUTION:
Be extremely careful not to spill brake fluid. Brake fluid spilt on the vehicle body will harm the paint surface; wipe it off quickly if spilt.





INSTALLATION
1. Install the master cylinder to body, and connect the clutch pipe to master cylinder.

NOTE:
Check that the pipe is routed properly.





2. Connect the push rod of master cylinder to clutch pedal, and install the clevis pin and snap pin.

NOTE:
Apply grease to the clevis pin.





3. After bleeding air from the clutch system, ensure that clutch operates properly.
4. Install the air intake chamber. (Non-turbo model)
5. Install the intercooler. (Turbo model)

DISASSEMBLY
1. Remove the straight pin and reservoir tank.





2. Remove the oil seal.





3. Move the cylinder boot backward.





4. Remove the snap ring.

CAUTION:
Be careful when removing the snap ring to prevent the rod, washer, piston and return spring from flying out.

5. Remove the clutch damper.

ASSEMBLY
1. Install the clutch damper.
Tightening torque:
46.6 Nm (4.75 kgf-m, 34.4 ft. lbs.)
2. Apply a coat of grease to the contacting surfaces of the push rod and piston before installation.
Grease:
SILICONE GREASE G-40M (Part No. 004404003)





3. Assemble in the reverse order of disassembly.
Tightening torque:
10 Nm (1.0 kgf-m, 7 ft. lbs.)

INSPECTION
If any damage, deformation, wear, swelling, rust or other faults are found on the cylinder, piston, push rod, fluid reservoir, return spring, gasket, clutch damper, cylinder boot and hose replace the faulty part.