Clutch Master Cylinder: Service and Repair

Master Cylinder

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





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

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





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

NOTE: Check that the pipe is routed properly.





2) Connect the push rod of the master cylinder to the 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 the 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 seat towards the rear.





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 N-m (4.75 kgf-m, 34.4 ft-lb)
2) Apply a coat of grease to the contact surfaces of the push rod and piston before installation.





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

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, seat or hose, replace the faulty part.