Clutch Master Cylinder (For Hatchback) -- Installation |
| 1. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS |
Install the lock nut to the push rod.
Text in Illustration *1 Lock Nut *2 Clutch Master Cylinder Push Rod Clevis
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Install the clutch master cylinder push rod clevis to the push rod.
Tighten the lock nut and check the dimension A is same as the dimension A that has been measured.
- Torque:
- 12 N*m{120 kgf*cm, 9 ft.*lbf}
- NOTICE:
- When tightening the lock nut, be sure to hold the clevis in place by its square portion.
| 2. INSTALL CLUTCH MASTER CYLINDER ASSEMBLY |
Apply MP grease to the contact surface of the clutch master cylinder push rod clevis and the clutch pedal sub-assembly.
Text in Illustration 
MP grease
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Install the clutch master cylinder push rod clevis to the cutout of the clutch pedal sub-assembly from the left side of the vehicle and push it downward.
Install the clutch master cylinder assembly with the 2 nuts.
- Torque:
- 9.0 N*m{92 kgf*cm, 80 in.*lbf}
| 3. CONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE TUBE |
Using a union nut wrench (10 mm), connect the clutch master cylinder to flexible hose tube to the clutch master cylinder assembly.
- Torque:
- 15 N*m{155 kgf*cm, 11 ft.*lbf}
- NOTICE:
- Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (YARIS_NCP93 RM00000482L007X.html).
| 4. INSTALL CLUTCH RESERVOIR TUBE |
Install the clutch reservoir tube to the clutch master cylinder assembly with the clip.
| 5. INSTALL BRAKE BOOSTER ASSEMBLY |
| 6. BLEED CLUTCH LINE |
- HINT:
- In case of clutch fluid replacement, make sure that the old fluid is replaced in the clutch line between the reservoir and the bleeder before bleeding.
Remove the release cylinder bleeder plug cap.
Text in Illustration *1 Release Cylinder Bleeder Plug Cap *2 Release Cylinder Bleeder Plug
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Connect a vinyl tube to the release cylinder bleeder plug.
Depress the clutch pedal 5 times, and then loosen the release cylinder bleeder plug while the pedal is depressed.
When fluid no longer comes out, tighten the release cylinder bleeder plug, and then release the clutch pedal.
Repeat both of the previous 2 steps 6 times.
Tighten the release cylinder bleeder plug.
- Torque:
- 8.3 N*m{85 kgf*cm, 73 in.*lbf}
Depress the clutch pedal 10 times or more and confirm its operation.
- NOTICE:
- This must be performed before the engine is started.
Install the release cylinder bleeder plug cap.
Check that all the air has been bled from the clutch line.
| 7. INSPECT FOR BRAKE FLUID LEAK |
| 8. INSPECT BRAKE FLUID LEVEL |
Check the fluid level.
If brake fluid level is lower than the MIN line, check for leaks and inspect the disc brake pads. If necessary, refill the reservoir with brake fluid to the MAX line after repair or replacement.Text in Illustration *a MAX Line *b MIN Line - Fluid:
- SAE J1703 or FMVSS No. 116 DOT 3
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| 9. INSPECT AND ADJUST CLUTCH PEDAL |