HHR 2006-2008

Master Cylinder

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the clutch pedal retainer from the front of the clutch pedal assembly.
  4.  
  5. Pull the clutch pedal upward in order to disengage the clutch master cylinder pushrod from the clutch pedal.

    Click image to see an enlarged view

    Fig. Remove the Underhood Electrical Center (UBEC)

  6.  
  7. Remove the Underhood Electrical Center (UBEC) using the following steps:
    1. Disconnect the negative battery cable.
    2.  
    3. Remove the cover (2) from the UBEC.
    4.  
    5. Remove the underhood positive battery terminal lug (4).
      NOTE
      Take note of the positioning of the positive battery cables before disconnecting the cables.

    6.  
    7. Disconnect the positive battery cables (5) from the UBEC.
      NOTE
      The UBEC bolts (3) are retained in the electrical center.

    8.  
    9. Loosen all of the UBEC bolts (3).
    10.  
    11. Remove the UBEC (1) from the vehicle.
      WARNING
      Avoid spilling brake fluid onto painted surfaces, electrical connections, wiring, or cables. Brake fluid will damage painted surfaces and cause corrosion to electrical components. If any brake fluid comes in contact with painted surfaces, immediately flush the area with water. If any brake fluid comes in contact with electrical connections, wiring, or cables, use a clean shop cloth to wipe away the fluid.

    12.  

  8.  
  9. Place a shop towel under the clutch master cylinder in order to catch any fluid loss.
  10.  
  11. Disconnect the clutch hose from the clutch master cylinder.
  12.  
  13. Disconnect the clutch line from the clutch master cylinder.
  14.  
  15. Cap the reservoir and hydraulic lines in order to prevent fluid loss and contamination.
  16.  
  17. Rotate the clutch master cylinder 1 / 4 turn clockwise and remove the cylinder from the vehicle.

    Click image to see an enlarged view

    Fig. Rotate the clutch master cylinder 1/4 turn clockwise to remove

  18.  

To install:


NOTE
While installing, ensure that the clutch master cylinder pushrod is aligned with the clutch pedal.

  1. Install the clutch master cylinder while rotating 1 / 4 turn counterclockwise.
  2.  
  3. Uncap the reservoir and hydraulic lines.
  4.  
  5. Connect the clutch line to the clutch master cylinder.
  6.  
  7. Connect the clutch hose to the clutch master cylinder.
  8.  
  9. Install the Underhood Electrical Center UBEC using the following steps:
    1. Place the UBEC (1) into position.
    2.  
    3. Tighten all of the UBEC bolts (3). Tighten the bolts to 89 inch lbs. (10 Nm).
    4.  
    5. Connect the positive battery cables (5) to the UBEC.
    6.  
    7. Install the underhood positive battery terminal lug (4). Tighten the terminal lug to 133 inch lbs. (15 Nm).
    8.  
    9. Install the cover (2) to the UBEC.
    10.  
    11. Connect the negative battery cable.
    12.  

  10.  
  11. Connect the clutch master cylinder pushrod to the clutch pedal.
  12.  
  13. Install the clutch pedal retainer.
  14.  
  15. Bleed the clutch hydraulic system. Refer to Hydraulic System Bleeding.
  16.  

 
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