ION, L-Series, S-Series 1999-2005

Master Cylinder

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Removal & Installation



  1. Clean the brake fluid reservoir cap and area around the cap.
  2.  
  3. Remove the brake fluid reservoir cap and remove enough brake fluid to clear the passage to the clutch master cylinder.

    Click image to see an enlarged view

    Fig. Remove the clutch hydraulic line assembly from the clutch master cylinder

  4.  
  5. Disconnect the clutch hydraulic line assembly from the body retaining clips.
  6.  
  7. Remove the clutch hydraulic line assembly from the clutch master cylinder.
  8.  
  9. Position the line out of the way of the clutch master cylinder removal path.

    Click image to see an enlarged view

    Fig. Remove the clutch master cylinder hose from the brake master cylinder

  10.  
  11. Remove the clutch master cylinder hose from the brake master cylinder.
  12.  
  13. Remove the left lower I/P closeout panel (hush panel) push pins and remove the left lower I/P closeout (hush panel).

    Click image to see an enlarged view

    Fig. Remove the clutch master cylinder push rod from the clutch pedal

  14.  
  15. Remove the clutch master cylinder push rod from the clutch pedal.
  16.  
  17. Remove the clutch master cylinder mounting nuts and remove the master cylinder.
  18.  

To install:

  1. Transfer the clutch master cylinder hose to the new clutch master cylinder.
  2.  
  3. Install the clutch master cylinder and mounting nuts, tighten the clutch master cylinder mounting nuts to 15 ft. lbs. (20 Nm).
  4.  
  5. Connect the clutch master cylinder rod to the clutch pedal.
  6.  
  7. Install the left lower I/P closeout panel (hush panel).
  8.  
  9. Install the clutch master cylinder hose to the brake master cylinder.
  10.  
  11. Attach the clutch hydraulic line assembly to the clutch master cylinder.
  12.  
  13. Connect the hydraulic line assembly to body retaining clips.
  14.  
  15. Add brake fluid as required and bleed the clutch hydraulic system.
  16.  
  17. Inspect the system for proper operation and fluid leaks. Repair as necessary.
  18.  


NOTE
The clutch master and actuator cylinder assembly is to be serviced as a complete unit. It is a sealed unit and has been filled with fluid and bled of air at the factory. Individual components of the system are not available for service, except the slave cylinder actuator pushrod plastic retainer strap

  1. Block clutch pedal up to prevent pedal from being depressed with slave cylinder removed from transaxle.

    Click image to see an enlarged view

    Fig. Remove the air cleaner and duct assembly

  2.  
  3. Remove the air cleaner and duct assembly.
  4.  
  5. Disconnect the negative battery cable from battery.
  6.  
  7. Disconnect the positive battery cable from battery.
  8.  
  9. Remove the hold-down retaining nut and screws, and lift off battery hold-down retainer.
  10.  
  11. Lift the battery out of the vehicle, and place it in a safe location.
    NOTE
     The PCM J. (black 80-way) harness connector does not need to be disconnected.

  12.  
  13. Disconnect the PCM J2 (black 28-way harness connector by moving the locking device outward toward the fender
  14.  
  15. Remove the PCM Attachment bolts and move the PCM out of the way.
  16.  
  17. Remove the battery tray and bolts. One bolt is located in the fender well
    NOTE
    Prior to removing the slave cylinder from the clutch hosing, make sure that the clutch hydraulic system has sufficient fluid.

  18.  
  19. Rotate the actuator quarter turn counterclockwise while pushing toward housing in order to disengage the bayonet connector and remove from clutch housing.
  20.  
  21. Remove the two hydraulic damper to clutch housing nuts and slide damper and bracket assembly off studs.
    NOTE
     Brake master cylinder does not need to be moved to gain access to clutch master cylinder assembly.



    Click image to see an enlarged view

    Fig. Remove the ABS control assembly

  22.  
  23. Remove the ABS control assembly.

    Click image to see an enlarged view

    Fig. Remove the clutch master cylinder pushrod retainer clip from clutch pedal pin and disconnect pushrod from pedal

  24.  
  25. Remove the clutch master cylinder pushrod retainer clip from clutch pedal pin and disconnect pushrod from pedal.
  26.  
  27. Turn the clutch master cylinder approximately eighth turn clockwise and remove from the dash.
  28.  
  29. Remove the clutch master and actuator assembly from the vehicle.
  30.  

To install:


NOTE
When installing a new unit, leave the clutch slave cylinder pushrod retainer in place when installing the unit. This will ensure the actuator rod is seated in the clutch release fork pocket as the actuator is installed.


NOTE
When installing an existing unit, a new clutch slave cylinder pushrod retainer should be installed on the end of the pushrod and the straps should be attached to the actuator.

  1. Install the clutch master cylinder into dash with reservoir leaning outboard. Turn approximately 1/8 turn counterclockwise to lock in position.
  2.  
  3. On ABS equipped vehicles, place the brake master cylinder back on the booster studs and tighten brake master cylinder-to-booster nuts. Tighten the brake master cylinder-to-brake booster nuts to 20 ft. lbs. (27 Nm ).
  4.  
  5. Slide the damper and bracket onto clutch housing damper studs and install the nuts, and tighten the clutch hydraulic damper bracket-to-case studs to 18 ft. lbs. (25 Nm ).
  6.  
  7. Install actuator into clutch housing with hydraulic line facing down and rotate actuator quarter turn clockwise while pushing toward housing.
  8.  
  9. Add dielectric (silicone) grease to clutch pedal pin then connect pushrod and install pushrod retainer clip to clutch pedal pin.
    NOTE
    ABS system must be bled.

  10.  
  11. Install ABS control assembly.
  12.  
  13. Install the battery tray and bolts. One bolt in fender well at location, and tighten the battery tray-to-frame rail bolts to 89 inch lbs.(10 Nm )
  14.  
  15. Install the PCM and PCM attachment bolts, and tighten the PCM-to-battery tray bolts to 53 inch lbs.(6 Nm )
  16.  
  17. Reconnect the PCM J2 (black 28 way) harness connector and secure locking device.
  18.  
  19. Make sure the battery tray is clean.
  20.  
  21. Make sure that the battery cable ends are clean and free of corrosion. (Clean with a wire brush.)
  22.  
  23. Make sure that the battery is in food physical condition (e.g., no cracks, or obvious damage) and that the terminals are clean.
  24.  
  25. Install the battery carefully in the battery tray; make sure that the terminals do not short against any metal during the installation.
  26.  
  27. Install the battery hold-down retainer, locking the battery into the tray. Install and tighten the hold-down retainer nut and screws, and tighten the battery hold down-to-battery tray fasteners to 80 inch lbs.(9 Nm ).
    NOTE
    Attach the positive then negative terminal.

  28.  
  29. Install the positive battery cable first, and tighten the battery terminal bolts to 13 ft. lbs. (17 Nm ).
    NOTE
    Attach positive then negative terminal.

  30.  
  31. Install the air cleaner and duct assembly, and tighten the air box attachment bolts to 89 inch lbs.(10 Nm ).
  32.  

  1. Remove the clutch pedal retainer from the front of the clutch pedal assembly.
  2.  
  3. Pull the clutch pedal upward in order to disengage the clutch master cylinder pushrod from the clutch pedal.
  4.  
  5. Remove the Underhood Electrical Center (UBEC).
  6.  
  7. Place a shop towel under the clutch master cylinder in order to catch any fluid loss.

    Click image to see an enlarged view

    Fig. Disconnect the clutch damper from the clutch master cylinder

  8.  
  9. Disconnect the clutch damper from the clutch master cylinder.

    Click image to see an enlarged view

    Fig. Disconnect the reservoir line from clutch master cylinder

  10.  
  11. Disconnect the reservoir line from clutch master cylinder.
  12.  
  13. Cap the reservoir and hydraulic lines in order to prevent fluid loss and contamination.

    Click image to see an enlarged view

    Fig. Rotate the clutch master cylinder one quarter turn clockwise and remove the cylinder from the vehicle

  14.  
  15. Rotate the clutch master cylinder one quarter turn clockwise and remove the cylinder from the vehicle.
  16.  

To install:


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

  1. Install the clutch master cylinder while rotating quarter turn counterclockwise.
  2.  
  3. Uncap the reservoir and hydraulic lines.
  4.  
  5. Connect the clutch damper to the clutch master cylinder.
  6.  
  7. Install the reservoir line in the clutch master cylinder.
  8.  
  9. Remove the shop towel and discard in a suitable container.
  10.  
  11. Install the UBEC.
  12.  
  13. Connect the clutch master cylinder pushrod to the clutch pedal.
  14.  
  15. Install the clutch pedal retainer.
  16.  
  17. Bleed the clutch hydraulic system.
  18.  

  1. Remove the clutch pedal retainer from the front of the clutch pedal assembly.
  2.  
  3. Pull the clutch pedal upward in order to disengage the clutch master cylinder pushrod from the clutch pedal.
  4.  
  5. Remove the Under right hand hood Electrical Center (UBEC).
  6.  
  7. Place a shop towel under the clutch master cylinder in order to catch any fluid loss.

    Click image to see an enlarged view

    Fig. Disconnect the clutch damper from the clutch master cylinder

  8.  
  9. Disconnect the clutch damper from the clutch master cylinder.

    Click image to see an enlarged view

    Fig. Disconnect the reservoir line from clutch master cylinder

  10.  
  11. Disconnect the reservoir line from clutch master cylinder.
  12.  
  13. Cap the reservoir and hydraulic lines in order to prevent fluid loss and contamination.

    Click image to see an enlarged view

    Fig. Rotate the clutch master cylinder one quarter turn clockwise and remove the cylinder from the vehicle

  14.  
  15. Rotate the clutch master cylinder one quarter turn clockwise and remove the cylinder from the vehicle.
  16.  

To install:


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

  1. Install the clutch master cylinder while rotating quarter turn counterclockwise.
  2.  
  3. Uncap the reservoir and hydraulic lines.
  4.  
  5. Connect the clutch damper to the clutch master cylinder.
  6.  
  7. Install the reservoir line in the clutch master cylinder.
  8.  
  9. Remove the shop towel and discard in a suitable container.
  10.  
  11. Install the UBEC.
  12.  
  13. Connect the clutch master cylinder pushrod to the clutch pedal.
  14.  
  15. Install the clutch pedal retainer.
  16.  
  17. Bleed the clutch hydraulic system.
  18.  

 
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