Clutch Slave Cylinder: Service and Repair

Operating Cylinder
REMOVAL
1. Remove the air intake chamber. (Non-turbo model)
2. Remove the intercooler. (Turbo model)
3. Disconnect the clutch hose from the operating cylinder.

CAUTION:
- Cover the hose joint to prevent the clutch fluid from flowing out.
- Do not loosen or remove the cap bolts.

- 5MT model

NOTE: The illustration below is for a Non-turbo model. However, perform the same procedures for the Turbo model.





- 6MT model





4. Remove the operating cylinder from the transmission.
- 5MT model

NOTE: The illustration below is for a Non-turbo model. However, perform the same procedures for the Turbo model.





- 6MT model





INSTALLATION
1. 5MT MODEL
1. Install in the reverse order of removal.

NOTE:
- The illustration below is for a Non-turbo model. However, perform the same procedures for the Turbo model.
- Before installing the operating cylinder, apply grease (KOPR-KOTE: Part No. 003603001) to the contact point of the release lever and operating cylinder.

Tightening torque:
T1: 18 N-m (1.8 kgf-m, 13.3 ft-lb)
T2: 37 N-m (3.8 kgf-m, 27.3 ft-lb)





2. After bleeding air from the operating cylinder, ensure that the clutch operates properly.

2. 6MT MODEL
1. Install in the reverse order of removal.

NOTE: Before installing the operating cylinder, apply grease (KOPR-KOTE: Part No. 003603001) to the contact point of the release lever and operating cylinder.

Tightening torque:
T1: 18 N-m (1.8 kgf-m, 13.3 ft-lb)
T2: 41 N-m (4.2 kgf-m, 30.2 ft-lb)





NOTE:
- Be sure to install the clutch hose with the mark side facing upward.
- Be careful not to twist the clutch hose during installation.





2. After bleeding air from the operating cylinder, ensure that the clutch operates properly.

DISASSEMBLY
1. Remove the boots and push rod assembly.

NOTE:
- Only 5MT model can be disassembled.
- The illustration below is for a Non-turbo model.





2. Apply compressed air through clutch hose attaching port.

NOTE: Face the piston port down and place a piece of wood underneath to prevent the piston from popping out.





3. Separate the piston and piston spring.

NOTE: The illustration below is for a Non-turbo model.





ASSEMBLY

NOTE: During assembly, apply hydraulic oil to all parts.

Recommended brake fluid
FMVSS No. 116, fresh DOT3 brake fluid

1. Install the piston spring onto the piston.

NOTE:
- Only 5MT model can be assembled.
- The illustration below is for a Non-turbo model.





2. Insert piston to the operating cylinder.
3. Install push rod to the boot.
4. Install boot and push rod to the operating cylinder.

NOTE: The illustration below is for a Non-turbo model.





INSPECTION
1. Check the operating cylinder for damage. If operating cylinder is damaged, replace it.
2. Check the operating cylinder for fluid leakage or damage on the boot. If any leakage or damage is found, replace the operating cylinder.