GM Cavalier/Sunbird/Skyhawk/Firenza 1982-1994

Clutch Hydraulic System

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REMOVAL & INSTALLATION



See Figures 1, 2 and 3

The clutch hydraulic system used on 1985-94 models is serviced as a complete unit (except 1994 3.1L). It has been bled of air and filled with fluid. Individual components of the system are not available separately.



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Fig. Fig. 1: View of the clutch hydraulic system - 1985-87 vehicles



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Fig. Fig. 2: Clutch hydraulic system - 1988-89 vehicles



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Fig. Fig. 3: Location of the clutch hydraulic system components - 1990 vehicles

1.8L, 2.0L and 2.2L Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the hush panel from inside the vehicle.
  4.  
  5. Disconnect the clutch master cylinder pushrod from the clutch pedal.
  6.  
  7. Unfasten the clutch master cylinder retaining nuts at the front of the dash.
  8.  
  9. Remove the slave cylinder or actuator retaining nuts at the transaxle.
  10.  
  11. Remove the hydraulic system as a unit from the vehicle.
  12.  

To install:
  1. Install the new slave cylinder or actuator to the transaxle support bracket aligning the pushrod into the pocket on the clutch fork outer lever. Tighten the retaining nuts evenly to prevent damage to the slave cylinder. Tighten to 14-20 ft. lbs. (19-27 Nm).
  2.  

Do not remove the plastic pushrod retainer from the slave or actuator cylinder. The straps will break on the first clutch pedal application.

  1. Position the clutch master cylinder to the front of the dash. Install the retaining nuts and tighten the nuts evenly to prevent damage to the master cylinder. Tighten to 15-25 ft. lbs. (20-34 Nm).
  2.  
  3. Remove the pedal restrictor from the pushrod. Lube the pushrod bushing on the clutch pedal. Connect the pushrod to the clutch pedal and install the retaining clip.
  4.  
  5. If equipped with cruise control, check the switch adjustment at the pedal bracket.
  6.  


WARNING
When adjusting the cruise control switch, do not exert an upward force on the clutch pedal pad of more than 20 lbs. (89 N) or damage to the master cylinder pushrod retaining ring can result.

  1. Install the hush panel.
  2.  
  3. Press the clutch pedal down several times. This will break the plastic retaining straps on the slave or actuator cylinder pushrod. Do not remove the plastic button on the end of the pushrod.
  4.  
  5. Connect the negative battery cable.
  6.  

2.8L and 3.1L Engines
  1. Remove the air intake duct from the air cleaner.
  2.  
  3. Disconnect the negative, then the positive battery cables.
  4.  
  5. Remove the left fender brace, then unfasten the battery hold-down clamp bolt and remove the battery.
  6.  
  7. Detach the MAT or IAT sensor lead from the air cleaner.
  8.  
  9. Unfasten the PCV pipe retaining clamp from the air intake duct.
  10.  
  11. Remove the clamp fastening the air intake duct to the throttle body.
  12.  
  13. Unfasten the MAF sensor mounting bolts, then unfasten the air cleaner bracket mounting bolts at the battery tray.
  14.  
  15. Remove the air cleaner, mass air flow sensor and the air intake duct as an assembly.
  16.  
  17. Detach the electrical lead at the washer bottle. Unfasten the attaching bolts, then remove the washer bottle from the vehicle.
  18.  
  19. If equipped with cruise control, remove the mounting bracket retaining nuts from the strut tower.
  20.  
  21. Remove the hush panel/sound insulator from inside the vehicle.
  22.  
  23. Disconnect the clutch master cylinder pushrod from the clutch pedal.
  24.  
  25. Unfasten the clutch master cylinder retaining nuts at the front of the dash, then remove the master cylinder.
  26.  
  27. For 1993 vehicles, unfasten the clutch actuator cylinder quick disconnect fitting from the master cylinder line.
  28.  
  29. For 1993, vehicles, remove the transaxle, as outlined earlier in this section, then remove the clutch actuator cylinder from the transaxle.
  30.  
  31. For vehicles through 1992, remove the slave or actuator cylinder retaining nuts at the transaxle, then remove the hydraulic system as a unit from the vehicle.
  32.  

To install:
  1. For vehicles through 1992, install the new slave or actuator cylinder to the transaxle support bracket aligning the pushrod into the pocket on the clutch fork outer lever. Tighten the retaining nuts evenly to prevent damage to the slave cylinder. Tighten to 14-20 ft. lbs. (19-27 Nm).
  2.  

Do not remove the plastic pushrod retainer from the slave or actuator cylinder. The straps will break on the first clutch pedal application.

  1. For 1993 vehicles, install the clutch actuator cylinder to the transaxle, then install the transaxle assembly. Attach the quick connect fitting to the master cylinder line.
  2.  
  3. Position the clutch master cylinder to the front of the dash. Install the retaining nuts and tighten the nuts evenly to prevent damage to the master cylinder. Tighten to 15-25 ft. lbs. (20-34 Nm).
  4.  
  5. Remove the pedal restrictor from the pushrod. Lube the pushrod bushing on the clutch pedal. Connect the pushrod to the clutch pedal and install the retaining clip.
  6.  
  7. If equipped with cruise control, check the switch adjustment at the pedal bracket.
  8.  


WARNING
When adjusting the cruise control switch, do not exert an upward force on the clutch pedal pad of more than 20 lbs. (89 N) or damage to the master cylinder pushrod retaining ring can result.

  1. Install the hush panel/sound insulator.
  2.  
  3. For 1993 vehicles, bleed the hydraulic system, as outlined later in this section.
  4.  
  5. For vehicles through 1992, press the clutch pedal down several times. This will break the plastic retaining straps on the slave or actuator cylinder pushrod. Do not remove the plastic button on the end of the pushrod.
  6.  
  7. Install the washer bottle, then attach the electrical connection.
  8.  
  9. Install the air cleaner, mass air flow sensor and the air intake duct as an assembly.
  10.  
  11. Fasten the air cleaner bracket mounting bolts, and the MAF sensor mounting bolt.
  12.  
  13. Install the clamp retaining the air intake duct to the throttle body.
  14.  
  15. Fasten the PCV pipe retaining clamp to the air intake duct.
  16.  
  17. Attach the MAF sensor lead, then connect the MAT or IAT sensor lead at the air cleaner.
  18.  
  19. Install the battery and the left fender brace.
  20.  
  21. Connect the positive, then the negative battery cables.
  22.  
  23. Attach the air intake duct to the air cleaner.
  24.  

 
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