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Master Cylinder - RHD: Installation

NOTE: Vehicles equipped with a 1.6/2.0/2.4L (Non-Turbo) engine have one-piece master/slave cylinder assemblies. If the master cylinder requires replacement, the master AND slave cylinders must be replaced with a two-piece "quick-connect" system. If the slave cylinder requires replacement, the slave cylinder is serviced separately.
NOTE: Replacement master cylinder assemblies come pre-filled with fluid. No fluid service or system bleeding should be required, unless the hydraulic system has lost an excessive amount of fluid and has ingested air into the master or slave cylinder assembly.
  1. Carefully route hydraulic pipe into position as removed and install clutch master cylinder into position (Figure ). Rotate master cylinder to engage pedal bracket assembly. 2.0L models: Rotate master cylinder clockwise (facing dash from underhood) to install. 2.2L Turbo Diesel Models: Rotate master cylinder counter-clockwise (facing dash from underhood) to install. 
  2. Install and secure grommet (Figure ).
  3. Install hydraulic pipe into dash panel retainer (Figure ).
  4. Install clutch master cylinder reservoir (Figure ).
  5. Raise vehicle.
  6. Install clutch master cylinder hydraulic pipe into left rail retainer (Figure ).
  7. If master cylinder is being replaced, install service replacement slave cylinder. If original master cylinder is being re-used, install slave cylinder as shown in (Figure ) (Figure ).
  8. Diesel and Turbo Models:  Connect hydraulic pipe to clutch slave cylinder (Figure ). An audible "click" should be heard. Verify connection by pulling outward on connection.
  9. Lower vehicle.
  10. Connect clutch master cylinder rod to clutch pedal pin. An audible "click" should be heard. If damaged, replace nylon retainer.
  11. Install lower instrument panel bezel (Figure ).
  12. Connect battery negative cable.
  13. Install air cleaner assembly (Figure ).
  14. Verify that reservoir is full. Top off with DOT 3 brake fluid if necessary.
  15. Actuate clutch pedal a minimum of ten times to allow any air ingested into the system to vent to the master cylinder reservoir.
  16. Verify proper clutch release system operation. Excessive residual air in the system can be identified by a spongy pedal and/or improper clutch operation. If necessary, bleed clutch hydraulic system. (Refer to CLUTCH - STANDARD PROCEDURE  )
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