CLUTCH MASTER CYLINDER REMOVAL/INSTALLATION

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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.

1.  Disconnect the negative battery cable.

2.  Remove the battery and battery tray.

(See BATTERY REMOVAL/INSTALLATION [ZJ, ZY, Z6].)

(See BATTERY REMOVAL/INSTALLATION [LF, L3].)
(See BATTERY REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)
(See BATTERY REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

3.  For R.H.D. (L3 Turbo), remove the insulator.

(See EXHAUST SYSTEM REMOVAL/INSTALLATION [L3 Turbo].)

4.  Separate the steering shaft.

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.)

L.H.D.

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1
Reserve hose
(See Clutch Pipe and Clutch Reserve Hose Removal Note [L.H.D.].)
(See Clutch Pipe and Clutch Reserve Hose Installation Note [L.H.D.].)
2
Clutch pipe
(See Clutch Pipe and Clutch Reserve Hose Removal Note [L.H.D.].)
(See Clutch Pipe and Clutch Reserve Hose Installation Note [L.H.D.].)
3
Nuts
4
Clutch pedal component
(See CLUTCH PEDAL REMOVAL/INSTALLATION.)
5
Clutch master cylinder
(See Clutch Master Cylinder Removal Note.)
(See Clutch Master Cylinder Installation Note.)

R.H.D.

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1
Reserve hose
(See Clutch Pipe and Clutch Reserve Hose Removal Note [R.H.D.].)
(See Clutch Pipe and Clutch Reserve Hose Installation Note [R.H.D.].)
2
Clutch pipe
(See Clutch Pipe and Clutch Reserve Hose Removal Note [R.H.D.].)
(See Clutch Pipe and Clutch Reserve Hose Installation Note [R.H.D.].)
3
Nuts
4
Clutch pedal component
(See CLUTCH PEDAL REMOVAL/INSTALLATION.)
5
Clutch master cylinder
(See Clutch Master Cylinder Removal Note.)
(See Clutch Master Cylinder Installation Note.)


Clutch Pipe and Clutch Reserve Hose Removal Note [L.H.D.]

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 Pipe and Clutch Reserve Hose Removal Note [R.H.D.]

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. (Except L3 Turbo)

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2.  Disconnect the reserve hose from the clutch master cylinder using a flathead screwdriver as shown in the figure. (L3 Turbo)

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3.  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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4.  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.

L.H.D.

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R.H.D.

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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.

L.H.D.

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R.H.D.

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Clutch Master Cylinder Installation Note

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

L.H.D.

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R.H.D.

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

L.H.D.

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R.H.D.

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Clutch Pipe and Clutch Reserve Hose Installation Note [L.H.D.]

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.


Clutch Pipe and Clutch Reserve Hose Installation Note [R.H.D.]

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.

am2zzw00003960

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.

am3zzw00003772

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. (Except L3 Turbo)

6.  Insert the reserve hose straight into the clutch master cylinder as shown in the figure. (L3 Turbo)

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7.  Press the clip in after the reserve hose is inserted completely. (L3 Turbo)

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