Clutch Master Cylinder Removal and Installation: Installation

WARNING: This page is about a different car, the 2004 Suzuki XL-7 and 2004 Suzuki Grand Vitara. However, it is still accessible from the selected car via links, so may be relevant.

To bleed air from master cylinder (1) itself, tilt it as shown in figure and add fluid into it.
NOTE: After bleeding air from master cylinder (1), plug pipe hole in it to prevent fluid from spilling out of it till pipe is connected.

Fig 1: Tilting Fluid Reservoir
Courtesy of SUZUKI OF AMERICA CORP.
Install master cylinder assembly and new gasket to body, attaching bolt (1), nuts (2) and push rod clevis pin (3).
NOTE: Do not reuse gasket.
Torque attaching bolt (1) and nut (2) to specification.
Connect fluid pipe and torque flare nut (4) to specification.
Tightening torque

Clutch master cylinder mounting bolt and nut (a): 13 N.m (1.3 kg-m, 9.5 lb-ft)

Clutch fluid pipe flare nut (b): 16 N.m (1.6 kg-m, 11.5 lb-ft)
Apply grease to clevis pin (3) and install it.
"A": Grease 99000-25010

Fig 2: Installing Master Cylinder
Courtesy of SUZUKI OF AMERICA CORP.
Fill reservoir with specified brake fluid and check fluid leakage.
After installation, bleed air from system and check clutch pedal free travel. Refer to BLEEDING BRAKE SYSTEM for air bleeding procedure.

Fig 3: Bleeding Air From System
Courtesy of SUZUKI OF AMERICA CORP.