Master Cylinder - RHD

Fig 1: Clutch Master Cylinder Mounting - RHD

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1 - RESERVOIR

Install clutch master cylinder (1) into position but do not fasten to brake pedal bracket at this time. Carefully route hydraulic pipe into position as removed. See Fig 1.

Fig 2: Master Cylinder Pipe At Left Rail
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1 - RETAINER

2 - MASTER CYLINDER PIPE
Fasten hydraulic supply tube to retainer (1) at left rail. See Fig 2.

Fig 3: Hydraulic Tube Retaining Clips
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1 - RETAINER CLIPS

Connect hydraulic supply tube to clutch slave cylinder:

1.6L/2.4L N/A Models: Raise vehicle on hoist. Insert tube into slave cylinder port, depress both retaining clips (1) to secure and verify connection by pulling outward. Lower vehicle. See Fig 3.
2.4L Turbo & 2.2L Diesel Models: Insert tube into slave cylinder port, depress both retaining clips to secure and verify connection by pulling outward.

Fig 4: Clutch Master Cylinder Supply Hose

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1 - BRAKE MASTER CYLINDER RESERVOIR

2 - HOSE CLAMP

3 - CLUTCH MASTER CYLINDER SUPPLY HOSE

Connect clutch master cylinder supply hose (3) to brake master cylinder reservoir (1) and secure with clamp (2). See Fig 4.

Fig 5: Opening Hydraulic Circuit Bleed - 1.6L/2.4L

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1 - RETAINING RING

2 - CLEAR HOSE

3 - HYDRAULIC TUBE

Fig 6: Hydraulic Tube Retaining Clips

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1 - RETAINER CLIPS

Fig 7: Releasing Inboard Retainer - Typical

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1 - INBOARD RETAINER

Fill clutch hydraulic release system with fluid:

1.6L/2.4L N/A Models: Fill brake master cylinder to the top with suitable DOT3 fluid. Leave cap off. Raise vehicle on hoist.
Remove bleed port protective cap and install suitable size and length of clear hose to monitor and divert fluid into suitable container.
Release only the lower hydraulic tube snap ring, pull outward on tube (2) until it stops against the second ring, opening up the bleed circuit and starting the air purge and fluid fill process. See Fig 5.
Lower vehicle, but only enough to gain access to and fill the brake master cylinder.
Top off brake master cylinder fluid level while air is purged and fluid drains from bleed port. Continue this until no air bubbles are seen and a solid column of fluid exists.
Close hydraulic bleed circuit. Insert hydraulic pipe fully into slave cylinder and depress retaining ring (1). See Fig 6. Remove drain hose.
2.4L Turbo & 2.2L Turbo Diesel Fill brake master cylinder to the top with suitable DOT3 fluid. Leave cap off.
Remove bleed port protective cap and install suitable size and length of clear hose to divert fluid into suitable container.

Release only the inboard hydraulic tube snap ring (1). See Fig 7.

Fig 8: Opening Hydraulic Circuit Bleed Port

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1 - CLEAR HOSE

2 - HYDRAULIC TUBE

3 - INNER RETAINER RING

Pull outward on tube (2) until it stops against the second ring, opening up the bleed circuit and starting the fluid fill process. See Fig 8.
Top off brake master cylinder fluid level while air is purged and fluid drains from bleed port. Continue this until no air bubbles are seen and a solid column of fluid exists.
Close hydraulic bleed circuit. Insert hydraulic pipe fully into slave cylinder and depress retaining ring. Remove drain hose (1).

CAUTION: Due to clutch master cylinder design and placement, the master cylinder body traps a significant amount of air which does not purge by means of normal methods. It is necessary to position master cylinder body vertical, with pushrod pointing down, for about ten seconds to purge air trapped from end of cylinder. Failure to perform this step upon assembly will result in inadequate system bleeding and poor release system functionality.

Fig 9: Clutch Master Cylinder Mounting - RHD

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1 - RESERVOIR

Verify that brake master cylinder reservoir is full and cap is off.
Remove clutch master cylinder body from dash panel. Position master cylinder body vertically, with pushrod pointing down, for about ten seconds to purge air trapped from end of cylinder. Install brake master cylinder cap.
Install clutch master cylinder body (1) through dash panel to pedal bracket assembly and rotate to secure. See Fig 9. 1.6/2.4L models: Rotate master cylinder clockwise (facing dash from underhood) to install. 2.2L Turbo-Diesel Models: Rotate master cylinder counter-clockwise (facing dash from underhood) to install.

Install and secure grommet. See Fig 9.

Fig 10: Brake Booster Mounting Nuts

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1 - CLIP

2 - BOOSTER MOUNTING NUTS

3 - BOOSTER MOUNTING NUTS

From inside vehicle, connect clutch master cylinder rod to clutch pedal pin. An audible "click" should be heard. If damaged, replace nylon retainer.
Install brake booster into position. Connect push rod to brake pedal pin.
Install and torque brake booster-to-dash panel nuts (2,3) to 34 N.m (300 in. lbs.). Install push rod retaining clip (1). See Fig 10.
Replace stop lamp switch.

Fig 11: Lower Instrument Panel Bezel
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Install lower instrument panel bezel (2). See Fig 11.
Install PDC bracket into position.
Raise vehicle on hoist.
Connect battery negative cable.

Fig 12: Removing/Installing Air Cleaner Assembly
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1 - AIR CLEANER ASSEMBLY
Install air cleaner assembly (1). See Fig 12.
Verify that brake master cylinder reservoir is full. Top off with DOT 3 brake fluid if necessary.
Actuate clutch pedal a minimum of fifty times to allow any air ingested into the system to vent to the master cylinder reservoir. If residual air becomes trapped in the system, it is necessary to bleed the clutch hydraulic system. See STANDARD PROCEDURE .
Verify proper clutch release system operation.