GM Corsica/Beretta 1988-1996 Repair Guide

Clutch Master and Slave (Actuator) Cylinder

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A hydraulic clutch mechanism is used on all clutch equipped vehicles. This mechanism uses a clutch master cylinder with a remote reservoir and a slave cylinder connected to the master cylinder. Whenever the system is disconnected for repair or replacement, the clutch system must be bled to insure proper operation.

REMOVAL & INSTALLATION



1988-89 Vehicles and 1990-96 2.2L Engine

See Figures 1 and 2

The clutch master and slave cylinders are removed from the vehicle as an assembly. After installation the clutch hydraulic system must be bled.

  1. Disconnect the negative battery cable.
  2.  
  3. From inside the vehicle, remove the hush panel.
  4.  

If equipped with a 2.8L engine, remove the air cleaner assembly.

  1. Disconnect the clutch master cylinder push rod from the clutch master cylinder.
  2.  
  3. From the front of the dash, remove the trim cover.
  4.  
  5. Remove the clutch master cylinder-to-clutch pedal bracket nuts and the remote reservoir-to-chassis screws.
  6.  
  7. Remove the slave cylinder-to-transaxle nuts and the slave cylinder.
  8.  
  9. Remove the hydraulic system (as a unit) from the vehicle.
  10.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the clutch hydraulic system components - 1988-89 vehicles



Click image to see an enlarged view

Fig. Fig. 2: Clutch slave (actuator) installation - 1990-96 2.2L engines

To install:
  1. Install the slave cylinder-to-transaxle support, align the push rod to the clutch fork outer lever pocket. Tighten the slave cylinder-to-transaxle support nuts to 16 ft. lbs. (22 Nm).
  2.  

If installing a new clutch hydraulic system, DO NOT break the push rod plastic retainer; the straps will break on the first pedal application.

  1. Install the master cylinder-to-clutch pedal bracket. Torque the nuts evenly (to prevent damaging the master cylinder) to 15-20 ft. lbs. and reverse the removal procedures. Remove the pedal restrictor from the push rod. Lubricate the push rod bushing on the clutch pedal; if the bushing is cracked or worn, replace it.
  2.  
  3. If equipped with cruise control, check the switch adjustment at the clutch pedal bracket.
  4.  

When adjusting the cruise control switch, do not exert more than 20 lbs. of upward force on the clutch pedal pad for damage to the master cylinder push rod retaining rod can result.

  1. Depress the clutch pedal several times to break the plastic retaining straps; DO NOT remove the plastic button from the end of the push rod.
  2.  
  3. To complete the installation, reverse the removal procedures.
  4.  
  5. Bleed the clutch hydraulic system.
  6.  

1992-96 2.3L and 3.1L Engines

The clutch master and slave cylinders are removed from the vehicle as an assembly. After installation the clutch hydraulic system must be bled.

  1. Disconnect the negative battery cable.
  2.  
  3. From inside the vehicle, remove the hush panel.
  4.  
  5. Remove the air cleaner duct assembly.
  6.  
  7. Disconnect the left fender brace.
  8.  
  9. Remove the battery.
  10.  
  11. Disconnect the MAT/IAT sensor lead at the air cleaner.
  12.  
  13. Disconnect the Mass Air Flow (MAF) sensor lead.
  14.  
  15. Remove the PCV pipe retaining clamp at the air intake duct.
  16.  
  17. Remove the clamp retaining the air intake duct to the throttle body.
  18.  
  19. Remove the MAF sensor.
  20.  
  21. Remove the air cleaner bracket mounting bolts at the battery tray.
  22.  
  23. Remove the air cleaner, Mass Air Flow sensor and the air intake duct as an assembly.
  24.  
  25. Disconnect the electrical lead at the washer bottle, remove the attaching bolts and remove the bottle.
  26.  
  27. Disconnect the cruise control mounting bracket retaining nuts from the strut tower, if equipped.
  28.  
  29. Disconnect the clutch master cylinder push rod from the clutch pedal.
  30.  
  31. From the front of the dash, remove the trim cover, if so equipped.
  32.  
  33. Remove the clutch master cylinder retaining nuts at the dash.
  34.  
  35. Remove the actuator cylinder-to-transaxle nuts.
  36.  
  37. Remove the hydraulic system (as a unit) from the vehicle.
  38.  

To install:
  1. Install the actuator cylinder-to-transaxle support, align the push rod to the clutch fork outer lever pocket. Tighten the slave cylinder-to-transaxle support nuts to 16 ft. lbs. (22 Nm).
  2.  


WARNING
If installing a new clutch hydraulic system, DO NOT break the push rod plastic retainer; the straps will break on the first pedal application.

  1. Install the master cylinder to the front of the dash. Tighten the nuts evenly (to prevent damaging the master cylinder) to 16 ft. lbs. (22 Nm). Remove the pedal restrictor from the push rod. Lubricate the push rod bushing on the clutch pedal; if the bushing is cracked or worn, replace it.
  2.  
  3. If equipped with cruise control, check the switch adjustment at the clutch pedal bracket.
  4.  

When adjusting the cruise control switch, do not exert more than 20 lbs. of upward force on the clutch pedal pad for damage to the master cylinder push rod retaining rod can result.

  1. Depress the clutch pedal several times to break the plastic retaining straps; DO NOT remove the plastic button from the end of the push rod.
  2.  
  3. Install the washer bottle and connect the electrical lead.
  4.  
  5. Install the air cleaner, Mass Air Flow (MAF) sensor and the air intake duct as an assembly.
  6.  
  7. Install the air cleaner bracket mounting bolts at the battery tray.
  8.  
  9. Install the Mass Air Flow (MAF) sensor.
  10.  
  11. Install the clamp retaining the air intake duct to the throttle body.
  12.  
  13. Install the PCV pipe retaining clamp at the air intake duct.
  14.  
  15. Connect the MAF sensor lead.
  16.  
  17. Attach the MAT/IAT sensor lead at the air cleaner.
  18.  
  19. Install the battery.
  20.  
  21. Connect the left fender brace.
  22.  
  23. Install the air cleaner duct assembly.
  24.  
  25. From inside the vehicle, install the hush panel.
  26.  
  27. Connect the negative battery cable.
  28.  

 
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