Clutch master cylinder — removal and installation

Removal

1. Remove the center cowl cover and the under-cowl panel (see Body).

2. Working under the dashboard, remove the cotter pin or spring clip from the master cylinder pushrod clevis. Pull out the clevis pin to disconnect the pushrod from the pedal. Unscrew the two clutch master cylinder retaining nuts.

3. Use a syringe or other suitable method, to remove and properly dispose of the hydraulic fluid from the clutch master cylinder reservoir.

Caution: Don’t allow brake fluid to come into contact with the paint as it will damage the finish.

4. Remove the air filter housing and air cleaner bracket (see Fuel and exhaust systems). Release the clutch hydraulic line from the retaining clamp that secures it to the coolant line. On 1.8L models, remove the battery and battery tray (see Engine electrical systems), the brake fluid reservoir (see Brakes) and ECM/PCM harness. The ECM/PCM connectors are labeled with symbols to identify their locations.

5. Disconnect the steel clutch line from the fitting where it joins the flexible clutch hose. Have rags handy as some fluid will be lost as the line is removed. Cap or plug the ends of the line (and/or hose) to prevent fluid leakage and the entry of contaminants. Clamp a pair of locking pliers onto the clutch fluid feed hose, a couple of inches downstream of the reservoir. The pliers should be just tight enough to prevent fluid flow when the hose is disconnected.

6. Remove the clutch master cylinder from the firewall with the hydraulic fluid reservoir and hydraulic lines still attached, then disconnect the clutch fluid feed hose and the hydraulic line at the cylinder. Again, have rags handy and cap or plug the ends of the lines (and/or hose) to prevent fluid leakage.

Caution: Don’t allow brake fluid to come into contact with the paint as it will damage the finish.

Installation

7. Installation is the reverse of removal, noting the following points:

  1. ) Use new gasket between the master cylinder and the firewall. Tighten the master cylinder mounting nuts to the torque listed in this Chapter’s Specifications.
  2. ) Install a new 0-ring seal and retainer clip on the hydraulic line fitting at the master
  3. ) Fill the clutch master cylinder reservoir with brake fluid conforming to DOT 3 specifications and bleed the clutch system as outlined see Clutch hydraulic system — bleeding.

  • Pages

    open all | close all