Clutch Master Cylinder: Service and Repair

Master Cylinder

REMOVAL

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

1) Drain the clutch fluid. Clutch Fluid Inspection & Replacement
2) Remove the cover assembly - instrument panel LWR driver.
3) Remove the snap pin and clevis pin, and then separate the push rod of the master cylinder from clutch pedal.





4) Remove the air intake boot assembly.
5) Disconnect the clutch pipe and tank hose from the master cylinder.
6) Remove the master cylinder.





INSTALLATION

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

Tightening torque:
T1: 15 Nm (1.5 kgf-m, 11.1 ft-lb)
T2: 18 Nm (1.8 kgf-m, 13.3 ft-lb)





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

CAUTION:
Always use a new clevis pin.

NOTE:
Apply grease to the clevis pin.





3) Install the cover assembly - instrument panel LWR driver.
4) After bleeding air from the clutch system, ensure that the clutch operates properly.
5) Install the air intake boot assembly.

DISASSEMBLY

1) Remove the straight pin and nipple.





2) Remove the oil seal.





3) Move the seat towards the rear.





4) Remove the piston stop ring.

CAUTION:
When removing the piston stop ring, be careful to prevent the rod, washer, piston and return spring from popping out.

ASSEMBLY

1) Apply a coat of grease to the contact surfaces of the push rod and piston before installation.

Grease:
SILICONE GREASE G-40M or equivalent





2) Assemble in the reverse order of disassembly.

Tightening torque:
10 Nm (1.0 kgf-m, 7.4 ft-lb)

INSPECTION

If any damage, deformation, wear, swelling, rust or other faults are found on the cylinder, piston, push rod, nipple, return spring, breather screw, seat or hose, replace the faulty part.