Neon, 2000-2005

Hydraulic System

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Bleeding The Hydraulic System




NOTE
It is necessary to bleed the clutch hydraulic system if the system has lost an excessive amount of fluid and has gotten into the circuit. Air in the system typically results in a spongy pedal feel, and/or improper clutch release. If air cannot be removed from the system using this procedure, it is necessary to replace BOTH the clutch master cylinder and slave cylinder assemblies.

2.0L Engine

From driver's seat, actuate clutch pedal 60-100 times. Verify clutch operation/pedal feel. If pedal still feels spongy, or clutch does not fully disengage, excessive air is still trapped within the system. Perform the following procedure:

  1. Verify fluid level in clutch master cylinder reservoir. Top off with DOT 3 brake fluid as necessary.
  2.  
  3. Raise vehicle on hoist.
  4.  
  5. Remove clutch slave cylinder assembly from the transaxle case, but do not disconnect from the system. Allow the slave cylinder hang, making it the lowest part of the system.
    WARNING
    While slave cylinder is detached from the transaxle, DO NOT actuate the clutch master cylinder. Damage to the slave cylinder will result.



    Click image to see an enlarged view

    Fig. Clutch slave cylinder (1) and bracket (2) at transaxle-2.0L models

    Clutch slave cylinder (1) and bracket (2) at transaxle-2.0L models
  6.  
  7. Depress slave cylinder pushrod until it bottoms and then release. Repeat this at least ten (10) times, forcing trapped air upwards and out of the system.
  8.  
  9. Re-install slave cylinder into position. Torque slave cylinder to case bolt to 14 ft. lbs. (19 Nm).
  10.  
  11. Lower vehicle.
  12.  
  13. Check and adjust clutch master cylinder fluid level. Actuate clutch pedal thirty (30) times. Verify clutch operation/pedal feel. If pedal still feels spongy, or clutch does not fully disengage, air is still trapped within the system. Repeat bleeding procedure until air is purged. If several attempts at purging air from the system are unsuccessful, replace both the clutch master cylinder and slave cylinder assemblies.
  14.  
  15. Raise vehicle.
  16.  
  17. Lower vehicle.
  18.  
  19. Top off clutch master cylinder fluid level with DOT 3 brake fluid as necessary.
  20.  

2.4L Turbo Engine

From driver's seat, actuate clutch pedal 60-100 times. Verify clutch operation/pedal feel. If pedal still feels spongy, or clutch does not fully disengage, excessive air is still trapped within the system. Perform the following procedure:

  1. Verify fluid level in clutch master cylinder reservoir. Top off with DOT 3 brake fluid as necessary.
  2.  
  3. Raise vehicle on hoist.
  4.  
  5. Remove clutch slave cylinder/damper assembly from the transaxle case, but do not disconnect from the hydraulic system. Lift nylon tab with a small screwdriver, and then depress cylinder inward toward case and rotating cylinder 60° counter-clockwise. Allow the slave cylinder hang, making it the lowest part of the system.
    WARNING
    While slave cylinder is detached from the transaxle, DO NOT actuate the clutch master cylinder. Damage to the slave cylinder will result.



    Click image to see an enlarged view

    Fig. Mounting hole (1), slave cylinder (2), access hole (3) and nylon anti-rotation tab (4)

    Mounting hole (1), slave cylinder (2), access hole (3) and nylon anti-rotation tab (4)
  6.  
  7. Depress slave cylinder pushrod until it bottoms and then release. Repeat this at least ten (10) times, forcing trapped air upward and out of the system.
  8.  
  9. Install clutch slave cylinder into position, noting orientation of different sized lugs. While depressing inward, rotate slave cylinder clockwise until nylon locating tab rests in transaxle case cutout, and the hydraulic tube is vertical.
  10.  
  11. Lower vehicle.
  12.  
  13. Check and adjust clutch master cylinder fluid level. Actuate clutch pedal thirty (30) times. Verify clutch operation/pedal feel. If pedal still feels spongy, or clutch does not fully disengage, air is still trapped within the system. Repeat bleeding procedure until air is purged. If several attempts at purging air from the system are unsuccessful, replace both the clutch master cylinder and slave cylinder assemblies. Raise vehicle.
  14.  
  15. Lower vehicle.
  16.  
  17. Top off clutch master cylinder fluid level with DOT 3 brake fluid as necessary.
  18.  

 
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