Clutch Master Cylinder Removal/Installation

WARNING: This page is about a different variant/trim than selected.

CAUTION:

Secure the steering wheel using tape or a cable to prevent the steering shaft from rotating after disconnecting the steering shaft. If the steering wheel rotates after the steering shaft and the steering gear and linkage are disconnected, the internal parts of the clock spring could be damaged.
Do not allow clutch fluid get on a painted surface. Clutch fluid contains properties which can dissolve the paint. If clutch fluid gets on a painted surface, wash it off with water immediately and wipe the area off completely.

Disconnect the negative battery cable.
Remove the battery component. (ex: battery, battery tray) (See BATTERY REMOVAL/INSTALLATION [MZR 2.5] .)
Remove the starter interlock switch. (See STARTER INTERLOCK SWITCH REMOVAL/INSTALLATION .)
Remove the clutch pedal position switch. (See CLUTCH PEDAL POSITION SWITCH REMOVAL/INSTALLATION .)
Remove the Joint cover. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION .)
Disconnect the steering shaft from steering gear. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION .)
Disconnect the clutch pipe and hose No.1 from clutch master cylinder, and plug it to avoid clutch fluid leakage. (See CLUTCH PIPE AND HOSE REMOVAL/INSTALLATION .)
Disconnect the clutch reserve hose from clutch master cylinder, and plug it to avoid clutch fluid leakage. (See CLUTCH PIPE AND HOSE REMOVAL/INSTALLATION .)
Remove the clutch pedal installation nuts.

Fig 1: Identifying Clutch Pedal Installation Nuts

Tightening torque
- 19-25 N.m {2.0-2.5 kgf.m, 15-18 ft.lbf}
Remove the clutch master cylinder.
1. Disconnect the clutch master cylinder (rubber) from the body.
2. Rotate the clutch master cylinder in the direction of the arrow shown in the figure to disconnect the clutch master cylinder (body) and clutch pedal.
  
  Fig 2: Rotating Clutch Master Cylinder
3. Disengage the tabs of the push rod and remove the clutch master cylinder using a flathead screwdriver.
  
  Fig 3: Removing Clutch Master Cylinder Using Flathead Screwdriver
Install the clutch master cylinder.
1. Insert the clutch master cylinder into the installation hole of the body.
2. Insert the stud bolt into the installation hole of the clutch pedal.
  
  Fig 4: Inserting Stud Bolt Into Installation Hole Of Clutch Pedal
3. Engage the tabs of the push rod with the clutch pedal as shown in the figure.
  
  Fig 5: Engaging Tabs Of Push Rod With Clutch Pedal
4. Rotate the clutch master cylinder in the direction shown until it stops.
  
  Fig 6: Rotating Clutch Master Cylinder
5. Install the clutch master cylinder (rubber) to the body.
Install in the reverse order of removal.
Bleed the air from the clutch system. (See CLUTCH FLUID REPLACEMENT/AIR BLEEDING .)
Fully depress the clutch pedal, and verify that the engine starts.