CLUTCH MASTER CYLINDER REMOVAL/INSTALLATION [EXCEPT MZR 2.0 DISI i-stop]

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Caution
•  Fluid will damage painted surfaces. Be careful not to spill any on painted surfaces. If it is spilled, wipe it off immediately.
Note
•  If clutch system-related hydraulic parts are removed, supply brake fluid, bleed air, and inspect for fluid leakage after the installation.

1.  Remove the battery cover. (Z6, MZ-CD 1.6 (Y6), LF, L5)(See BATTERY REMOVAL/INSTALLATION [ZY, Z6].)(See BATTERY REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)(See BATTERY REMOVAL/INSTALLATION [LF, L5].)

2.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [ZY, Z6].)(See BATTERY REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)(See BATTERY REMOVAL/INSTALLATION [LF, L5].)(See BATTERY REMOVAL/INSTALLATION [MZR-CD 2.2].)

3.  Remove the battery and battery tray. (L.H.D.) (See BATTERY REMOVAL/INSTALLATION [ZY, Z6].)(See BATTERY REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)(See BATTERY REMOVAL/INSTALLATION [LF, L5].)(See BATTERY REMOVAL/INSTALLATION [MZR-CD 2.2].)

4.  Remove the Insulator. (R.H.D., L3 Turbo)(See EXHAUST SYSTEM REMOVAL/INSTALLATION [L3 Turbo].)

5.  Remove in the order indicated in the table.

6.  Plug the clutch pipe after removing it to avoid leakage.

7.  Install in the reverse order of removal.

8.  Bleed the air from the system. (See CLUTCH FLUID AIR BLEEDING/REPLACEMENT.)

9.  After installation, inspect the clutch pedal. (See CLUTCH PEDAL INSPECTION/ADJUSTMENT.)

L.H.D.

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R.H.D.

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1
Clutch reserve hose
(See Clutch Pipe and Clutch Reserve Hose Removal Note.)
(See Clutch Pipe and Clutch Reserve Hose Installation Note.)
2
Clutch pipe
(See Clutch Pipe and Clutch Reserve Hose Removal Note.)
(See Clutch Pipe and Clutch Reserve Hose Installation Note.)
3
Clutch pedal position switch connector
4
Clutch pedal position switch
(See Clutch Pedal Position Switch Installation Note.)
5
Nut
6
Clutch pedal component
7
Clutch master cylinder
(See Clutch Master Cylinder Removal Note.)
(See Clutch Master Cylinder Installation Note.)


Clutch Pipe and Clutch Reserve Hose Removal Note

Caution
•  When disconnecting the clutch pipe, the seal ring installed to the end of the clutch pipe connector may fall off or remain on the clutch master cylinder side. If the clutch pipe is assembled with the seal ring not installed, it may cause fluid leakage from the clutch pipe connector or the clutch may not operate normally. When disconnecting the clutch pipe, remove the seal ring and clutch pipe connector as a single unit.
Note
•  A seal ring has been installed to the mid-connector between the clutch master cylinder and clutch release cylinder. Verify that the clutch pipe is removed together with the seal ring when disconnecting the mid-connector.
•  The O-ring type mid-connector seal ring is installed to the groove at the end of the clutch pipe.

1.  Remove the reserve hose from the master cylinder while pressing the point indicated by the arrow in the figure.

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2.  Pull the clutch master cylinder clip to the position shown in the figure and pull out the clutch pipe connector straight to detach it.

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3.  Verify that the seal ring is removed together with the clutch pipe connector.

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Clutch Master Cylinder Removal Note

1.  Rotate the clutch master cylinder in the direction shown and remove.

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2.  Press on the tabs on the left and right sides of the push rod using a flathead screwdriver and remove the rod.

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Clutch Master Cylinder Installation Note

1.  Push the push rod in until the tabs lock.

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2.  Rotate the clutch master cylinder in the direction shown until it stops.

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Clutch Pedal Position Switch Installation Note

1.  Insert a new clutch pedal position switch into the pedal bracket hole until the switch stops.

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2.  Rotate the clutch pedal position switch 45° clockwise.

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3.  Verify that the clutch pedal position switch is locked securely.


Clutch Pipe and Clutch Reserve Hose Installation Note

Note
•  A seal ring has been installed to the mid-connector between the clutch master cylinder and clutch release cylinder. Verify that a seal ring is installed to the clutch pipe when connecting the mid-connector.
•  The O-ring type mid-connector seal ring is installed to the groove at the end of the clutch pipe.

1.  Verify that the seal ring is assembled to the clutch pipe so that the ends of the seal ring and the clutch pipe overlap each other.

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Caution
•  Verify that there is no chipping or damage to the seal ring of the clutch pipe connector.

2.  Return the clutch master cylinder clip to the position shown in the figure.

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3.  Insert the clutch pipe connector straight.

4.  Pull the clutch pipe to verify that it does not come off, and reinsert it completely.

5.  Insert the reserve hose connector straight until a click is heard.

6.  Pull the reserve hose to verify that it does not come off, and reinsert it completely.