CLUTCH MASTER CYLINDER REMOVAL/INSTALLATION [C66M-R]

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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 to get on a painted surface. Clutch fluid contains properties which can dissolve the paint. If clutch fluid gets on a painted surface, rinse with water immediately, then wipe the area dry.

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2.  Remove the following parts as a single unit. (L.H.D.) (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT CYLINDER DEACTIVATION)] .)

•  Air cleaner cover

•  Air cleaner element

•  Fresh-air duct

•  Air cleaner case

•  Air hose

•  Resonance chamber

3.  Remove the battery. (L.H.D.) (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT CYLINDER DEACTIVATION)].)

4.  Remove the PCM component. (L.H.D.) (See PCM REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT CYLINDER DEACTIVATION)].)

5.  Remove the battery tray. (L.H.D.) (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT CYLINDER DEACTIVATION)].)

6.  Remove the insulator. (R.H.D.) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT CYLINDER DEACTIVATION)].)

7.  Remove the clutch master cylinder using the following procedure. (See Clutch Master Cylinder Installation Note.)

(1)  Disconnect the clutch stroke sensor connector.

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(2)  Remove the bracket from the steering shaft. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)

(3)  Disconnect the connectors and wiring harness clip shown in the figure from the clutch pedal and set the wiring harness aside.

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(4)  Remove the clutch pedal position switch. (See CLUTCH PEDAL POSITION SWITCH REMOVAL/INSTALLATION [C66M-R].)

(5)  Remove the starter interlock switch. (See STARTER INTERLOCK SWITCH REMOVAL/INSTALLATION [C66M-R].)

(6)  Remove the joint cover. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)

(7)  Disconnect the steering shaft from steering gear. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)

(8)  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 [C66M-R].)

(9)  Disconnect the clutch reserve hose from clutch master cylinder, and plug it to avoid clutch fluid leakage. (See CLUTCH PIPE AND HOSE REMOVAL/INSTALLATION [C66M-R].)

(10)  Remove the clutch pedal and the clutch master cylinder as a single unit.

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(11)  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.

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(12)  Disengage the tabs of the push rod and remove the master cylinder.

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8.  Install in the reverse order of removal.

9.  Fully depress the clutch pedal, and verify that the engine starts.

Clutch Master Cylinder Installation Note

1.  Engage the tabs of the push rod with the clutch pedal as shown in the figure.

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

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3.  Install the clutch pedal and the clutch master cylinder as a single unit. (See CLUTCH PEDAL REMOVAL/INSTALLATION [C66M-R].)

4.  Connect the clutch reserve hose to clutch master cylinder. (See CLUTCH PIPE AND HOSE REMOVAL/INSTALLATION [C66M-R].)

5.  Connect the clutch pipe and hose No.1 to clutch master cylinder. (See CLUTCH PIPE AND HOSE REMOVAL/INSTALLATION [C66M-R].)

6.  Connect the steering shaft. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)

7.  Install the joint cover. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)

8.  Bleed the air from the clutch system. (See CLUTCH FLUID REPLACEMENT/AIR BLEEDING [C66M-R].)

9.  Inspect the clutch pedal. (See CLUTCH PEDAL INSPECTION [C66M-R].)

10.  Install a new starter interlock switch. (See STARTER INTERLOCK SWITCH REMOVAL/INSTALLATION [C66M-R].)

11.  Install a new clutch pedal position switch. (See CLUTCH PEDAL POSITION SWITCH REMOVAL/INSTALLATION [C66M-R].)

12.  Connect the connectors, wiring harness clip and wiring harness shown in the figure to the clutch pedal.

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13.  Install the bracket to the steering shaft. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)

14.  Connect the clutch stroke sensor connector.

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