CLUTCH MASTER CYLINDER

Problem - Where is the clutch master cylinder and how do you fill the reservoir?

Possibility 1 - The clutch master cylinder is located behind the panel (facing fire wall) in the trunk. 

Possibility 2 - It is marked 1. on the parts diagram. The slave cylinder is marked 19.

Possibility 3 - If it is faulty, just replace the seals. There is no need to purchase a new one.

Possibility 4 - The master cylinder unbolts from the wall by the pedal assembly.

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REPLACING AND REFILLING PROCESS

In order to replace the clutch master, the panel in the trunk needs to be removed, some of the bolts on mine were replace with easy twist lock/unlock type which are quite handy, but there are still 2 allen bolts to remove.

Push the washer bottle through the hole while pulling the cover.

Gently lay the panel on its face.

The clutch master is it there.

Only one pipe goes into the unit.

Remove the cap followed by a small mesh filter that sits inside the plastic container.

Pieces removed.

Place some rags below the master cylinder. Remember clutch fluid can ruin and damage paint and other stuff. Wipe up immediately if any spills.

Once you get as much out as possible, loosen the metal clutch line. Loosen it and pull it out to one side. They will be heaps of room to move it.

Cylinder is now drained. Leave the rags in place still. The master cylinder is bolted from the inside. Two bolts hold it in place through the firewall and a nut and bolt through the fork to the clutch pedal.

The hardest bolt to reach is the one on the top side of the rubber boot.

Take the nut/bolt off the fork first.

Remove the bolts holding the cylinder. make sure you get all the washers and remember the orientation of each of them.

All is now free. Back to the trunk and slide the old cylinder out.

Old one and the bits.

Time to reinstall. Slip the new unit back into the position.

Put the pipe back into position, but don't tighten fully yet.

Back into the footwell. The new unit is through.

Start bolting it all back together. No need for huge amounts of torque here.

Now tighten up the hard line.

The new clutch master cylinder is installed. Now bleed the system. Use the same pump (cleaned) to refill the cylinder.

Open and bleed the cylinder on the slave cylinder.

Remove the rubber cap.

Have one person pump the pedal while the other opens and closes the bleed screw and keep filling the master cylinder.

You can use an old jar, clear hose and bleed nipple adapter to do this job. Attach this to the bleed nipple.

I must apologize for the next bit as I was unable to photograph the pumping of the clutch pedal, while opening and closing the bleed nipple etc, could have been doing with a third person to take pics. But basically my bro is in the car, and im underneath at the slave cylinder, I open the bleed nipple and yell "PUMP" My bro pushes the clutch pedal in, and keeps it there, a few seconds later I close the bleed nipple and he pull the pedal out The above process is repeated many times, until I can see the fluid running nice and thick through the clear hose and its "bubble" free [no air] You also need to keep popping out to refill the master cylinder as it doesnt hold much fluid. I worked out that my bro pumped 6 times, and then I filled the cylinder again, safer this way and stops you sucking air in again. So all finished, put the filter back in and the new cap, wipe down the area if there is any spillage and that's it.

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