5 Speed Manual 02J

5 Speed Manual 02J

Master Cylinder, Removing and Installing

Special tools

- 3309 Release tool

- 10-208 A Pliers

Removing

- Obtain radio code on vehicles with coded radio,
- Switch ignition off and disconnect battery Ground strap.

- Remove intake hose -1- and connector -2- from air mass meter.
- Remove bolts -3-,-4- and -5-.
- Remove complete air cleaner.

Vehicles With 2.0L Engines

- Remove protective housing for relays from cable channel.

Continued For All Vehicles

- Remove supply hose -A- from brake fluid reservoir and seal.
- Remove control module and ABS hydraulic unit.
- Pry clip -B- for line/hose assembly out of master cylinder.
- Remove line/hose assembly -C- from master cylinder and seal.
- Remove driver's side lower cover.
- Remove clutch pedal switch, if part of orignal equipment.

- Now remove complete clutch pedal mounting bracket as follows:
- Remove connecting plate -A- first (arrows -1-).
- Remove nuts (arrows -2-) for mounting bracket -B-.
- Take off mounting bracket.

- Separate master cylinder operating rod from clutch pedal as follows:
- Insert release tool 3309 in clutch pedal cutout (arrow -A-). The inscription "top/oben" (-B-) must point away from clutch pedal.
- With pliers 10-208A positioned in recesses (arrow -C-) press tool together.

- Turn clutch pedal limit stop -A- in direction of arrow and remove.

- Push slave cylinder in direction of arrow -1- until stop.
- It must not be covered in the upper area by the over-center spring mounting (arrow -2-)

- Swing slave cylinder in direction of arrow -3- out of mounting bracket.

Installing

Install the clutch slave cylinder in the reverse order of removal and note the following:

- Install retainer -A- to master cylinder operating rod -B-.
- Press clutch pedal in direction of arrow to engage. Ensure correct location.

- Insert clutch pedal limit stop -A- again.
- Installation position: The arm (arrow) must point towards master cylinder -B-.
- Bleed clutch system after installing master cylinder.