Clutch Master Cylinder Removal and Installation

NOTE:
Use fender covers to avoid damaging painted surfaces.
Do not spill brake fluid on the vehicle; it may damage the paint or plastic. If brake fluid gets on the paint or plastic, wash it off immediately with water.
Plug the ends of the reservoir hose and flare nut to prevent spilling brake fluid.
The illustration show K24W1 engine.

1. Front Tower Bar - Remove

Remove the front tower bar.

2. Air Cleaner - Remove

Remove the air cleaner.

3. Battery - Remove

Do the battery removal procedure.

4. PCM with Bracket - Remove (K24W1 Engine)
1.
Disconnect the PCM connectors (A).
2.
Remove the harness clamps (B).
3.
Remove the harness holder (C).
4.
Remove the PCM (D) with the bracket.

5. Battery Base - Remove
1.
Remove the battery base (A).
2.
Remove the harness clamps (B).

6. Clutch Reservoir - Remove
1.
Remove and discard the brake fluid from the clutch reservoir (A) with a syringe or other suitable device.
2.
Remove the clutch reservoir.

7. Under-Hood Fuse/Relay Box Bracket - Remove
1.
Remove the nut (A).
2.
Remove the clamps (B).
3.
Move the under-hood fuse/relay box (C) out of the way.
4.
Remove the harness clamp (A).
5.
Remove the under-hood fuse/relay box bracket (B).

8. Driver's Dashboard Undercover - Remove (If Equipped)

Remove the driver's dashboard undercover.

9. Clutch Master Cylinder - Remove
1.
Pry out the lock pin (A), and pull the clevis pin (B) out of the clevis.
2.
Remove the master cylinder mounting nuts (C).
3.
Disconnect the clutch line (A) from the clutch hose (B).
4.
Remove the clutch line from the clamp (C).
5.
Remove the clutch master cylinder (A) with the clutch line (B) and the reservoir hose (C).
6.
Remove the clutch master cylinder seal (D).
7.
Remove the reservoir hose (A).
NOTE: Inspect the hose. If the hose has damage, leaks, interference, or twisting, replace it.
8.
Remove the retaining clip (B) for disconnecting the clutch line (C) from the clutch master cylinder (D).

9.
Remove the O-ring (E).

1. Clutch Master Cylinder - Install
1.
Install a new O-ring (A) on the clutch line (B).
NOTE:
Apply the silicone grease (P/N 08C30-B0234M) to the O-ring and the end (C) of the clutch line.
Make sure not to get any silicone grease on the terminal part of the connectors and switches, especially if you have silicone grease on your hands or gloves.
2.
Install the clutch line in the clutch master cylinder (D) with a new retaining clip (E).
3.
Install the reservoir hose (F).
4.
To prevent the retaining clip (A) from coming off, pry apart the tip (B) of the clip with a flat-tipped screwdriver.




Clutch master cylinder side

Clutch reservoir side
5.
Make sure the hose clamps (A) are positioned on the clutch master cylinder (B) and the clutch reservoir (C) as shown.
NOTE: The hose clamps center of tang shall be in the area (D).
6.
Install the clutch master cylinder (A) with a new clutch master cylinder seal (B).
7.
Connect the clevis (A) to the clutch pedal (B).
8.
Apply multipurpose grease between the clutch pedal and the clevis.
NOTE: Wipe off any excess grease.
9.
Install the master cylinder mounting nuts (C).
10.
Apply multipurpose grease to the clevis pin (D).
11.
Slide the clevis pin into the clevis, then install the lock pin (E).
12.
Install the clutch line (A) to the clamp (B).
13.
Connect the clutch line to the clutch hose (C).

2. Under-Hood Fuse/Relay Box Bracket - Install
1.
Install the under-hood fuse/relay box bracket (A).
2.
Install the harness clamp (B).
3.
Install the under-hood fuse/relay box (A).

3. Clutch Reservoir - Install
Install the clutch reservoir (A).


4. Clutch Hydraulic System - Bleed
2.
Check the clutch operation and check for leaking fluid.

5. Battery Base - Install
1.
Install the battery base (A).
2.
Install the harness clamps (B).

6. PCM with Bracket - Install (K24W1 Engine)
1.
Install the PCM (D) with the bracket.
2.
Install the harness holder (E).
3.
Connect PCM connectors A, B, and C.
NOTE: PCM connectors A, B, and C have symbols (A=?, B=?, C=?) embossed on them for identification.
4.
Install the harness clamps (F).

8. Air Cleaner - Install

Install the air cleaner.

9. Front Tower Bar - Install

Install the front tower bar.

10. Clutch Pedal and Clutch Pedal Position Switch - Adjust

Adjust the clutch pedal and the clutch pedal position switch.

11. Test Drive - Check

Test-drive the vehicle.