02J, 5 SPD. M/T

Master cylinder, removing and installing, 02J, 5 Spd. M/T

Special tools and equipment

3309 Release tool:

10-208 A Pliers:

Removing
- Obtain radio code on vehicles with coded radio.
- With ignition switched off disconnect battery ground (GND) strap.





- Pull intake hose -1- and connector -2- off Mass Air Flow (MAF) sensor.
- Remove bolts -3, -4- and -5-.
- Remove air cleaner complete.

Vehicles with 2.0L engine
- Remove protective housing for relays from cable channel.

Continued for all vehicles





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





- Now remove complete clutch pedal mounting bracket as follows:
- Remove connecting plate -A- first (arrows 1).
- Remove securing 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 cut-outs (arrow -A-). Inscription "top/open" (-B-) points away from clutch pedal.
- With pliers 10-208A positioned in recesses (arrow -C-), press release tool together.





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





- Push slave cylinder in direction of (arrow -1-) until stop.
- It must not be covered in upper area by over-center spring mounting (arrow -2-).
- Swing slave cylinder in direction of (arrow -3-) out of mounting bracket.

Installing
Installation is carried out in the reverse sequence, when doing this note the following:





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





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