Warning! The brake fluid used in the hydraulic clutch system is poisonous, so if it comes into contact with the skin, immediately wash the area with plenty of water. If the liquid gets into the eyes or inside the body, you should immediately consult a doctor. Some fluids tend to be highly flammable and can ignite even from contact with hot vehicle components. In addition, the fluid used in the hydraulic clutch system dissolves paint and plastic, so if fluid comes into contact with the car's paintwork, wash it with plenty of water. Also, this liquid is hygroscopic, i.e. it absorbs moisture from the air and, therefore, it is not recommended to use liquid stored for a long time in an open container.
Removing
Clutch Master Cylinder
A - clutch master cylinder; B - rubber hose coupling; C - connecting hose; D - nuts; E - clutch pedal servo spring; F - retaining ring; G - pedal bracket
Removing the servo spring seat and washer from the push rod
After raising the clutch pedal, remove the servo-spring socket from the pusher (1), servo spring (2) and puck (3).
1. The clutch master cylinder is attached to the clutch and brake pedal bracket (see fig. Clutch Master Cylinder). Fluid is supplied to the clutch master cylinder through a flexible rubber hose from the brake fluid reservoir located in the engine compartment.
2. Remove the ground wire from the battery.
3. Remove the trim on the bottom of the instrument panel on the driver's side.
4. Peel back the carpet under the pedals and cover the floor with rags to collect fluid that has leaked from the hydraulic clutch system.
5. To reduce fluid loss, using a clean syringe, pump out the maximum amount of fluid from the appropriate chamber of the brake reservoir so that the fluid level drops below the clutch master cylinder supply hose connection.
6. Place a suitable container under the clutch master cylinder.
7. Unscrew the fasteners and disconnect the hydraulic tube from the clutch master cylinder. Plug the hole in the tube and clutch master cylinder to prevent dirt from entering and reduce fluid loss.
8. Remove the two nuts securing the clutch master cylinder to the pedal bracket.
9. Raise the clutch pedal and remove the servo spring housing, servo spring and washer from the push rod (see fig. Removing the servo spring seat and washer from the push rod).
10. Using a screwdriver blade, remove the circlip securing the clutch master cylinder pushrod to the pedal.
11. Disconnect the supply hose from the clutch master cylinder and remove the clutch master cylinder from the vehicle.
Disassembly and assembly
Place of fastening of a dustproof cover of a pusher to the case of the main cylinder of coupling
Removing the circlip from the clutch master cylinder
Removing the washer from the clutch master cylinder
Removing the pusher and piston from the clutch master cylinder housing
Removing the spring from the clutch master cylinder housing
Removing the plug and control valve from the piston end
1. Remove the pushrod dust cover from the clutch master cylinder housing (see fig. Place of fastening of a dustproof cover of a pusher to the case of the main cylinder of coupling).
2. Using special pliers, remove the retaining ring and remove the washer (see fig. Removing the retaining ring from the clutch master cylinder, Removing the washer from the clutch master cylinder).
3. Remove the pusher and piston together with the spring from the channel of the clutch master cylinder (see fig. Removing the pusher and piston from the clutch master cylinder housing, Removing the spring from the clutch master cylinder housing).
4. Remove the plug and control valve from the piston end (see fig. Removing the plug and control valve from the piston end).
5. Wash all parts of the clutch master cylinder in clean brake fluid and check their condition.
6. Check the condition of the clutch master cylinder bore and piston for wear and wear. If the clutch master cylinder bore is worn or deeply scratched, replace the clutch master cylinder assembly. If the parts of the clutch master cylinder are in satisfactory condition, replace the rubber o-rings.
7. Carefully remove the old o-ring from the piston. Dip the new o-ring in clean brake fluid and, being careful, install it on the piston so that the lips of the new o-ring are on the spring side of the piston.
8. Lubricate the clutch master cylinder passage and piston with clean brake fluid and insert the spring into the cylinder.
9. Install the check valve and plug on the piston and, being careful, insert the piston into the bore of the clutch master cylinder.
10. Slightly press the push rod into the clutch master cylinder, install the washer and circlip into the groove of the clutch master cylinder channel.
11. Reinstall the pushrod dust cover and secure it to the clutch master cylinder housing.
Installation
1. Installation is carried out in the reverse order of removal, taking into account the following points.
2. Install the washer, servo spring, servo spring seat on the push rod, insert the push rod into the pedal bracket guide while depressing the clutch pedal.
3. Check that the clutch master cylinder pusher lug is flanged towards the clutch pedal.
4. Do not install the driver's side instrument panel lower trim until the pushrod has been adjusted.
5. Fill the hydraulic clutch system with fluid and bleed air from it.
6. Check pusher adjustment.