Clutch Operating Cylinder Assembly Removal and Installation

Removal

NOTICE:

•Brake fluid is extremely damaging to painted surfaces.
If brake fluid contacts painted surfaces, immediately wipe it off and flush the surfaces with water thoroughly.
•The clutch operating cylinder may lose its original performance if it is disassembled and reassembled.
Do not disassemble and repair the clutch operating cylinder.

1)Clean around brake master cylinder reservoir cap and remove fluid from brake master cylinder reservoir with syringe or the like.

2)Dismount transaxle assembly.

3)Remove clamp (1), to disconnect clutch pipe joint (2).

4)Loosen clutch fluid pipe flare nut (1) of clutch operating cylinder assembly (2).

5)Remove clutch pipe joint sleeve (3) from transaxle, and then remove clutch fluid pipe (4).

6)Remove clutch operating cylinder assembly from transaxle.

Installation

1)Install clutch operating cylinder assembly (2) to transaxle. Tighten new clutch operating cylinder assembly bolts temporarily by hand in numerical order (“1” – “3”) as shown in figure.

2)Tighten clutch operating cylinder assembly bolts to specified torque.

Tightening torque

Clutch operating cylinder assembly bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)

3)Connect clutch fluid pipe (4) to clutch operating cylinder assembly temporarily.

4)Install clutch pipe joint sleeve (3) to transaxle securely and then tighten clutch fluid pipe flare nut (1) to specified torque.

Tightening torque

Clutch fluid pipe flare nut (b): 16 N·m (1.6 kgf-m, 12.0 lbf-ft)

5)Connect clutch pipe joint (2), and install clamp (1).

6)Remount transaxle assembly.

7)Bleed clutch system and check clutch pedal free travel.

•Air bleeding of clutch system:

•Clutch pedal free travel: