Clutch master cylinder ASSY (RHD model)
Components Removal / installation
CLUTCH
CLUTCH MASTER CYLINDER ASSY (RHD MODEL)
EXPLODED VIEW
REMOVAL
CAUTION:
·Do not let clutch fluid come into contact with the painted surface. If it is splashed, immediately wash it off with water.
·Be sure to remove the clutch master cylinder ASSY as a unit. Removing the clutch master cylinder-to-release cylinder hose pipe and the master cylinder-to-release cylinder hose on the vehicle can deform the clutch hose bracket.
·Be sure to remove the clutch master cylinder ASSY as a unit. Removing the clutch master cylinder-to-release cylinder hose pipe and the master cylinder-to-release cylinder hose on the vehicle can deform the clutch hose bracket.
1. Disconnection of battery ground terminal (refer to 
)
)2. Draining of clutch fluid
3. Removal of instrument side panel RH (refer to )
)4. Removal of instrument panel under cover SUB-ASSY No.1 (refer to )
)5. Removal of instrument panel under cover SUB-ASSY No.2 (refer to )
)6. Removal of knee airbag module (refer to )
)7. Disconnection of master cylinder-to-release cylinder hose (refer to )
)
8. Removal of clutch master cylinder ASSY
(1) Remove the clip from the push rod clevis pin.
(2) Remove the push rod clevis pin and disconnect the clutch master cylinder push rod clevis from the clutch pedal SUB-ASSY.
(3) Remove 2 nuts to remove the clutch hose bracket, clutch master cylinder ASSY, and seat.
(4) Secure the clutch master cylinder body through an aluminum plate with a vise.
CAUTION:
Do not vise excessively.
(5) Loosen the clutch master cylinder-to-release cylinder hose pipe nut.
(6) Release the clip, and remove the clutch master cylinder-to-release cylinder hose pipe and the master cylinder-to-release cylinder hose.
DISASSEMBLY
1. Removal of master cylinder reservoir SUB-ASSY.
(1) Remove the master cylinder reservoir cap.
(2) Secure the clutch master cylinder body through an aluminum plate with a vise.
CAUTION:
Do not vise excessively.
(3) Use a pin punch and hammer to drive out a pin.
(4) Remove the master cylinder reservoir SUB-ASSY from the clutch master cylinder body.
(5) Remove the grommet.
2. Removal of clutch master cylinder kit
ASSEMBLY
1. Installation of clutch master cylinder kit
(1) Apply SILICONE GREASE G40M or equivalent to the points shown in the figure.
Captions in illustration
 |
SILICONE GREASE G40M or equivalent |
(2) Install the compression spring, master cylinder piston SUB-ASSY, and clutch master cylinder push rod clevis to the clutch master cylinder body.
CAUTION:
Avoid damage to the inner surface of the clutch master cylinder body.
2. Installation of master cylinder reservoir SUB-ASSY
(1) Install the grommet.
(2) Install the master cylinder reservoir SUB-ASSY to the clutch master cylinder body.
(3) Use a pin punch and hammer to drive in a pin.
(4) Install the master cylinder reservoir cap.
INSTALLATION
1. Installation of clutch master cylinder-to-release cylinder hose pipe
(1) Install the master cylinder-to-release cylinder hose with the clip.
CAUTION:
·Install the clip securely as far as it will go.
·Install the master cylinder-to-release cylinder hose with the marking facing upward.
·Install the master cylinder-to-release cylinder hose with the marking facing upward.
(2) Tighten the clutch master cylinder-to-release cylinder hose pipe nut.
Standard value:
Standard value:
Tightening torque=15N·m
{
153kgf·cm}
{11.1ft·lbf}
CAUTION:
When tightening by combining a torque wrench and union nut wrench to extend the whole length, the actual torque will be excessive if tightened until the reading of the torque wrench reaches the specified tightening torque. (Refer to )
)2. Installation of clutch master cylinder ASSY
(1) Install the seat to the clutch master cylinder ASSY.
(2) Install the clutch master cylinder ASSY and the clutch hose bracket with the 2 nuts.
Standard value:
Standard value:
Tightening torque=18N·m
{
184kgf·cm}
{13.3ft·lbf}
(3) Apply NIGTIGHT LYW No.2 grease or equivalent to the outer surfaces of a new push rod clevis pin.
(4) Connect the clutch master cylinder push rod clevis to the clutch pedal with the push rod clevis pin.
NOTE:
Install the push rod clevis pin from the right side of vehicle.
(5) Install the clip to the push rod clevis pin.
(6) Connect the master cylinder-to-release cylinder hose to the clutch release cylinder ASSY with the union bolt through 2 new gaskets.
Standard value:
Standard value:
Tightening torque=18N·m
{
184kgf·cm}
{13.3ft·lbf}
CAUTION:
·When tightening by combining a torque wrench and union nut wrench to extend the whole length, the actual torque will be excessive if tightened until the reading of the torque wrench reaches the specified tightening torque. (Refer to )
·When restoring the clutch release cylinder ASSY, check that the clutch hose is deflected in the same direction as shown in the figure.
·Install the master cylinder-to-release cylinder hose with the marking facing upward.
)·When restoring the clutch release cylinder ASSY, check that the clutch hose is deflected in the same direction as shown in the figure.
·Install the master cylinder-to-release cylinder hose with the marking facing upward.
3. Connection of master cylinder-to-release cylinder hose (refer to )
)4. Filling of clutch fluid (refer to )
)5. Air bleeding of clutch pipeline (refer to )
)6. Clutch fluid leakage check
7. Clutch fluid amount check (refer to )
)8. Check/adjustment of clutch pedal (refer to )
)9. Installation of knee airbag module (refer to )
)10. Installation of instrument panel under cover SUB-ASSY No.2 (refer to )
)11. Installation of instrument panel under cover SUB-ASSY No.1 (refer to )
)12. Installation of instrument side panel RH (refer to )
)13. Connection of the battery ground terminal
Standard value:
Standard value:
Tightening torque=6.0N·m
{
61kgf·cm}
{4.4ft·lbf}
14. Settings when removing/installing battery terminals (refer to )
)15. Check of airbag warning light (refer to )
)