Removal and Installation Special Tool(s) | Remover/Installer, Clutch Master Cylinder 308-554 | Materials Name Specification Grease WSD-M1C230-A CAUTION:If brake fluid comes into contact with the paintwork, rinse off the affected areas with cold water without delay. All vehicles | -
Remove the air cleaner. For additional information, refer to: (303-12 Intake Air Distribution and Filtering) Air Cleaner - 1.6L Duratec-16V (Sigma) (Removal and Installation), Air Cleaner - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (Removal and Installation), Air Cleaner - 1.6L Duratorq-TDCi (DV) Diesel (Removal and Installation), Air Cleaner - 2.0L Duratorq-TDCi (DW) Diesel (Removal and Installation). | Left-hand drive vehicles | -
Remove the battery console. For additional information, refer to: (414-01 Battery, Mounting and Cables) Battery Tray - 1.6L Duratec-16V (Sigma)/1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (Removal and Installation), Battery Tray - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel (Removal and Installation). | RHD Vehicles | -
Disconnect the battery. For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures). | All vehicles | -
Extract brake fluid from the brake fluid reservoir until the level reaches the MIN mark. | | -
Remove the footwell side trim. | | -
Remove the lower footwell trim. | | -
Detach the data link connector (DLC) from the footwell lower trim. - Detach the data link connector clips.
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Detach the steering column shaft joint from the steering. - Remove the steering column shaft joint bolt.
| 9. Remove the components in the order indicated in the following illustration(s) and table(s). 2 - Clutch pedal return spring (vehicles with the 1.6L, 1.8L, 2.0L engine shown) 10. To install, reverse the removal procedure. All vehicles | -
Attach the steering column shaft joint to the steering. - Tighten the steering column shaft joint bolt.
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Attach the data link connector (DLC) at the footwell lower trim. - Install the data link connector clips.
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Install the lower footwell trim. | | -
Install the footwell side trim. | | -
Bleed the clutch system. For additional information, refer to: Clutch System Bleeding (308-00 Manual Transmission/Transaxle and Clutch - General Information, General Procedures). | Left-hand drive vehicles | -
Install the battery carrier. For additional information, refer to: (414-01 Battery, Mounting and Cables) Battery Tray - 1.6L Duratec-16V (Sigma)/1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (Removal and Installation), Battery Tray - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel (Removal and Installation). | RHD Vehicles | -
Connect the battery. For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures). | All vehicles | -
Install the air cleaner. For additional information, refer to: (303-12 Intake Air Distribution and Filtering) Air Cleaner - 1.6L Duratec-16V (Sigma) (Removal and Installation), Air Cleaner - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (Removal and Installation), Air Cleaner - 1.6L Duratorq-TDCi (DV) Diesel (Removal and Installation), Air Cleaner - 2.0L Duratorq-TDCi (DW) Diesel (Removal and Installation). | Vehicles with global closing | -
Initialize the window regulator motors. For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures). | Removal Details Item 1 : Clutch master cylinder pipes. | -
NOTE:The next step should only be performed on RHD vehicles. Raise vehicle for access For additional information, refer to: (100-02 Jacking and Lifting) Lifting (Description and Operation), Jacking (Description and Operation). | | -
CAUTION:Close off the clutch master cylinder line to prevent fluid loss or dirt ingress. Detach the clutch master cylinder pipes from the clutch master cylinder. - Press the clutch slave cylinder supply line lock button.
- Remove the clutch slave cylinder pressure line securing clip.
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NOTE:The next step should only be performed on RHD vehicles. Lower the vehicle. | Item 3 : Clutch pedal bracket nuts | -
Remove the clutch pedal bracket nuts. | Item 4 : Clutch pedal bracket | -
Detach the clutch pedal position (CPP) switch from the clutch pedal bracket. - Detach the cable from the wiring harness bracket.
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Detach the clutch master cylinder from the bulkhead using the special tool. - Turn the clutch master cylinder 60 degrees counter-clockwise.
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Remove the clutch master cylinder together with the clutch pedal bracket. - Turn the clutch pedal bracket to the position shown.
| Item 5 : Catch for clutch master cylinder actuating rod | -
Detach the clutch master cylinder from the clutch pedal bracket. - Press together the catch for the clutch master cylinder actuating rod.
| Installation Details Item 6 : Clutch master cylinder | -
NOTE:Coat the clutch master cylinder gaiter with grease before installing. Install the clutch master cylinder. | |