CLUTCH RELEASE CYLINDER (for 1WW) REMOVAL


  1. PRECAUTION

    Note

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here

  2. REMOVE NO.1 ENGINE UNDER COVER


    1. A01IR30

      Remove the 6 bolts and 11 clips.

    2. Remove the No. 1 engine under cover.

  3. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the reservoir cap and air release valve while the engine and radiator assembly are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. Loosen the radiator drain cock plug and drain the engine coolant.

      A01IUCQE01
      Text in Illustration
      *1 Reservoir Cap *2 Air Release Valve
      *3 Radiator Drain Cock Plug - -

      Tech Tips

      Collect the coolant in a container and dispose of it according to the regulations in your area.

    2. Remove the reservoir cap.

  4. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE ASSEMBLY


    1. A01IT1KE01
      Text in Illustration
      *1 Retainer

      Detach the clamp and disconnect the mass air flow meter sub-assembly connector.

    2. Detach the clamp and disconnect the vacuum hose from the air cleaner hose assembly.

    3. Detach the clamp and disconnect the No. 1 fuel hose from the air cleaner hose assembly.

    4. Detach the clamp and disconnect the No. 2 fuel hose from the air cleaner hose assembly.

    5. Disconnect the ventilation hose from the cylinder head cover sub-assembly.

    6. Release the retainer and disconnect the air cleaner hose assembly from the turbocharger sub-assembly as shown in the illustration.

    7. Detach the 2 clamps and remove the air cleaner cap sub-assembly with air cleaner hose assembly.

  5. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  6. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A01IN4S

      Remove the 3 bolts and air cleaner case sub-assembly.

  7. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  8. DISCONNECT CABLE FROM POSITIVE BATTERY TERMINAL

  9. REMOVE BATTERY CLAMP SUB-ASSEMBLY


    1. A01ININ

      Remove the bolt and loosen the nut.

    2. Detach the hook of the battery clamp sub-assembly from the battery carrier, and then remove the battery clamp sub-assembly.

  10. REMOVE BATTERY INSULATOR

  11. REMOVE BATTERY

  12. REMOVE BATTERY TRAY

  13. REMOVE BATTERY CARRIER ASSEMBLY


    1. A01IQXM

      Detach the 2 clamps and disconnect the engine wire.

    2. Remove the 4 bolts and battery carrier.

  14. REMOVE NO.1 AIR TUBE ASSEMBLY


    1. A01IN8C

      Slide the clamp and disconnect the water by-pass hose assembly from the No. 2 radiator pipe.

    2. Slide the clamp and disconnect the radiator hose sub-assembly from the No. 1 radiator pipe.

    3. Detach the clamp and disconnect the water hose sub-assembly from the compressor outlet elbow.

    4. Slide the clamp and disconnect the water hose sub-assembly from the No. 1 radiator pipe.

    5. Slide the clamp and disconnect the outlet heater water hose from the No. 2 radiator pipe.

    6. Remove the 2 bolts and disconnect the No. 1 air tube assembly from the manual transaxle assembly.

  15. DISCONNECT CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE


    1. A01INII

      Using a union nut wrench, disconnect the clutch release cylinder to flexible hose tube.

      Tech Tips

      Use a container to catch the fluid.

  16. REMOVE CLUTCH RELEASE CYLINDER ASSEMBLY


    1. A01IQ9C

      Remove the 2 bolts, clutch release cylinder assembly from the manual transaxle assembly.

  17. REMOVE CLUTCH RELEASE CYLINDER KIT


    1. Remove the boot from the release cylinder body.

    2. Remove the push rod from the release cylinder body.

    3. A01IR7F

      Using compressed air, remove the piston and spring from the release cylinder body.

      Note

      Do not damage the inside of the release cylinder body.

  18. REMOVE RELEASE CYLINDER BLEEDER PLUG


    1. Remove the bleeder plug cap from the bleeder plug.

    2. A01ISKR

      Remove the release cylinder bleeder plug from the release cylinder body.