Removal and Installation of Clutch Master Cylinder

REMOVAL
PROCEDURE

1. Disconnect the negative battery cable.

If the installed audio system has an anti-theft code, make sure you have the correct code to activate the audio system before disconnecting the battery!
2. Under the instrument panel, remove the pin and disconnect the clutch pedal pushrod clevis from the clutch pedal.

3. Disconnect the clutch master cylinder reservoir. Using self-locking pliers, pinch off the supply hose connecting the reservoir to the master cylinder.

Pinch the hose approximately 5 cm from the end fitted over the cylinder fitting. Disconnect the hose from the reservoir, remove the mounting bolt and remove the reservoir assembly from the engine compartment.
4. Loosen the retaining clamp and disconnect the hydraulic line from the master cylinder. To minimize brake fluid loss, wrap the fitting with a rag. Immediately plug the open ends of the line and fitting to prevent dirt from entering the system.

To prevent damage to the paint, do not allow hydraulic fluid to contact painted body panel surfaces.
5. Remove the power relay and its bracket from the wheel arch.

6. Inside the vehicle, under the instrument panel, remove the two nuts securing the master cylinder to the engine compartment bulkhead. Remove the cylinder from the vehicle.

INSTALLATION
PROCEDURE

1. Position the master cylinder in place and secure it with the bolts, finger-tightening the nuts.
2. Reconnect the hydraulic lines to their original positions. Tighten the retaining clamps.
3. Tighten the line fitting securely. Tighten the master cylinder mounting nuts to the specified torque.
4. Connect the pushrod to the clutch pedal and secure the clevis pin with a new pin.
5. Install the power relay and its bracket in their original position.
6. Remove the pliers from the supply hose. Fill the reservoir with the required amount of DOT 3 brake fluid, then bleed air from the system (see Bleeding Air from the Clutch Release Hydraulic System).