Honda Civic manuals

Honda Civic Service Manual: Clutch Master Cylinder Removal and Installation (K24Z7)

Honda Civic Service Manual / Powertrain / Transmission/Transaxle / Manual / Clutch / Clutch Master Cylinder Removal and Installation (K24Z7)

2111C5

NOTE:

Use fender covers to avoid damaging painted surfaces.

Do not spill brake fluid on the vehicle; it may damage the paint or plastic. If brake fluid does contact the paint or plastic, wash it off immediately with water.

Plug the ends of the hoses and joints to prevent spilling brake fluid.

Put on gloves to protect your hands.


1. Clutch Pedal


1.

Pry out the lock pin (A).


2.

Pull the clevis pin (B) out of the clevis.


3.

Remove the master cylinder mounting nuts (C).


2. Wiper Arm Assembly


NOTE: Set the wiper arms to the auto-stop position before removal.


1.

Remove the cowl top wiper covers (A).


2.

Remove the wiper arms (B).


3. Both Side Cowl Covers


1.

Remove the side cowl cover (A).


2.

The left side is shown; repeat on the right side.


4. Center Cowl Cover


1.

Remove the center cowl cover (A).


2.

Disconnect the windshield washer tube (B).


3.

If necessary, remove the hood rear seal (C).


5. Under Cowl Panel

1.

Remove the under cowl panel (A).


6. Clutch Fluid

1.

Remove and discard the brake fluid from the clutch reservoir with a syringe or other suitable device.


7. Air Cleaner Assembly


1.

Disconnect the intake air duct (A) and the intake air pipe (B).


2.

Remove the harness clamp (C).


3.

Remove the air cleaner (D).


8. Air Cleaner Bracket


1.

Remove the harness clamp (A).


2.

Remove the air cleaner bracket (B).


9. Clutch Master Cylinder


1.

Disconnect the clutch line (A) from the clutch hose (B).


2.

Remove the clutch line from the clamp (C).


3.

Remove the clutch master cylinder (A) with the clutch line (B) and the reservoir hose (C).



4.

Remove the reservoir hose (A).


5.

Remove the retaining clip (B) for disconnecting the clutch line (C) from the clutch master cylinder (D). Plug or wrap the end of the reservoir hose and the clutch line with a clean shop towel to prevent brake fluid from coming out.


NOTE: Inspect the hose. If the hose has damage, leaks, interference, or twisting, replace it.


6.

Remove the O-ring (E).


7.

Remove the clutch master cylinder seal (F).


1. Clutch Master Cylinder Push Rod Inspection

17inasmm

1.

Inspect the length (A) of the clutch master cylinder push rod to the figure as shown.


NOTE: When install the used clutch master cylinder only.


2. Clutch Master Cylinder


1.

Install a new O-ring (A) on the clutch line (B).


2.

Install the clutch line in the clutch master cylinder (C) with a new retaining clip (D).


NOTE:

Apply the silicone grease (P/N 08C30-B0234M) to the O-ring and the end (E) of the clutch line.

Make sure not to get any silicone grease on the terminal part of the connectors and switches, especially if you have silicone grease on your hands or gloves.


3.

Install the reservoir hose (F).


mm

4.

Make sure the hose clamp (A) is positioned on the clutch master cylinder (B) as shown.


NOTE: The hose clamp center of tang shall be in the area (C).


5.

To prevent the retaining clip (A) from coming off, pry apart the tip (B) of the clip with a screwdriver.


6.

Install the clutch master cylinder (A) with a new clutch master cylinder seal (B).



7.

Install the clutch line (A) to the clamp (B).


8.

Connect the clutch line to the clutch hose (C).


3. Clutch Pedal


1.

Install the master cylinder mounting nuts (A).


2.

Connect the clevis (B) to the clutch pedal, then apply multipurpose grease between the clutch pedal and the clevis.


NOTE: Wipe off any excess grease.


3.

Apply multipurpose grease to the clevis pin (C).


4.

Slide the clevis pin into the clevis.


5.

Install the lock pin (D).


4. Clutch Fluid

1.

Refill the brake fluid to the clutch reservoir.


5. Clutch Fluid Bleeding (K24Z7 Engine)

1.

Make sure the brake fluid level in the clutch reservoir (A) is at the MAX (upper) level line (B).



2.

Attach one end of a clear tube to the bleeder screw (A).


3.

Put the other end into a container.


4.

Loosen the bleeder screw to allow air to escape from the system.


5.

Make sure there is an adequate supply of fluid in the reservoir.


6.

Slowly push the clutch pedal all the way down.


7.

Before releasing the pedal, have an assistant temporarily tighten the bleeder screw.


8.

Loosen the bleeder screw, and push the clutch pedal down again.


9.

Repeat steps 2 through 8 until no more bubbles appear at the clear tube.


NOTE: Make sure the fluid level on the reservoir does not go below MIN.


10.

Tighten the bleeder screw securely.


11.

Refill the brake fluid in the reservoir to the MAX (upper) level line.


6. Air Cleaner Bracket


1.

Install the air cleaner bracket (A).


2.

Install the harness clamp (B).


7. Air Cleaner Assembly


1.

Install the air cleaner (A).


2.

Install the harness clamp (B).


3.

Connect the intake air pipe (C) and the intake air duct (D).


8. Under Cowl Panel

22mm)2222

1.

Install the under cowl panel (A).


9. Center Cowl Cover


1.

If necessary, install the hood rear seal (A).


2.

Connect the windshield washer tube (B).


3.

Install the center cowl cover (C).


10. Both Side Cowl Covers


1.

Install the side cowl cover (A).


2.

The left side is shown; repeat on the right side.


11. Wiper Arm Assembly

1.122


NOTE: Set the wiper arms to the auto-stop position before installation.


1.

Install the wiper arms (A).


2.

Install the cowl top wiper covers (B).


12. Clutch Pedal Stroke Check


1.

Disconnect the clutch pedal position switch B connector.


2.

Loosen the clutch pedal position switch B locknut (A).


3.

Back off clutch pedal position switch B until it no longer touches the clutch pedal (C).


4.

Pull the clutch pedal by hand, then turn clutch pedal position switch B until it contacts the clutch pedal.


5.

Turn in clutch pedal position switch B an additional 3/4 to 1 turn.


6.

Make sure the clutch pedal height did not change.


7.

While holding clutch pedal position switch B, tighten the locknut.


8.

Connect the clutch pedal position switch B connector.


9.

Measure the clutch pedal stroke (A).


(A) Clutch Pedal Stroke:

125-135 mm (4.92-5.31 in)

(B) Clutch Pedal Free Play (Reference):

7-18 mm (0.28-0.71 in)


(C) Clutch Pedal Height (Reference)*:

Without clutch pedal pad cover

151.8 mm
(5.976 in)

With clutch pedal pad cover

156 mm
(6.14 in)


*: Measure the clutch pedal height from right side middle of the clutch pedal cover or the clutch pedal pad cover (D) to the floor without the insulation.


(E) Clutch Pedal Disengagement Height (Reference)*:

Without clutch pedal pad cover

66.7-75.0 mm
(2.626-2.953 in)

With clutch pedal pad cover

69.7-78.1 mm
(2.744-3.075 in)


*: Measure the clutch pedal disengagement height from right side middle of the clutch pedal cover or the clutch pedal pad cover (D) to the floor without the insulation.


13. HDS DLC - Connection


1.

Connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard.


2.

Turn the ignition switch to ON (II).


3.

Make sure the HDS communicates with the vehicle. If it does not communicate, go to the DLC circuit troubleshooting.


14. Clutch Pedal Position Switch A Adjustment


1.

Loosen the clutch pedal position switch A locknut (B).


2.

Fully press the clutch pedal to the floor, then release the clutch pedal 17.5-22.5 mm (0.689-0.886 in) and hold it there.


NOTE: Measure the clutch pedal height from middle of the clutch pedal cover or the clutch pedal pad cover (C).


3.

Check CLUTCH PEDAL POSITION SWITCH A in the PGM-FI DATA LIST with the HDS.


4.

Adjust clutch pedal position switch A when the HDS screen indicates CLOSE to OPEN.


NOTE: Be careful not to twist the wire.


5.

While holding clutch pedal position switch A, tighten the locknut.


6.

Check the clutch pedal does not contact to the clutch pedal position switch A body when fully pressing the clutch pedal to the floor.


15. Clutch Operation Check

1.

Check the clutch operation.


2.

Check for leaks.


16. Test Drive

1.

Test-drive the vehicle.


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