Subaru Impreza 3 / Impreza WRX / Impreza WRX STI. Service manual — part 461

CL-19

Operating Cylinder

CLUTCH SYSTEM

5. Operating Cylinder

A: REMOVAL

1) Remove the intercooler. <Ref. to IN(STI)-12,

REMOVAL, Intercooler.> <Ref. to IN(w/o STI)-12,

REMOVAL, Intercooler.>

2) Disconnect the clutch hose from the operating

cylinder.
CAUTION:

• Cover the hose joint to prevent the clutch flu-

id from flowing out.

• Do not loosen or remove the cap bolts.

• STI model

• Except for STI model

3) Remove the operating cylinder from the trans-

mission.

• STI model

• Except for STI model

(A) Clutch hose
(B) Operating cylinder

(C) Cap bolt

(A) Clutch hose
(B) Operating cylinder

(C) Cap bolt

CL-00420

(B)

(A)

(C)

CL-00796

(A)

(B)

(C)

(A) Operating cylinder

(A) Operating cylinder

(A)

CL-00419

CL-00823

(A)

CL-20

Operating Cylinder

CLUTCH SYSTEM

B: INSTALLATION

1) Install in the reverse order of removal.
NOTE:

• Use a new gasket.

• Before installing the operating cylinder, apply

grease to the contact point of the release lever and

operating cylinder.
Grease

NICHIMOLY N-130 or equivalent

• Be sure to install the clutch hose with the mark

side facing upward.

• Be careful not to twist the clutch hose during in-

stallation.

• STI model
Tightening torque:

T1: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

T2: 41 N·m (4.2 kgf-m, 30.2 ft-lb)

• Except for STI model
Tightening torque:

T1: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

T2: 37 N·m (3.8 kgf-m, 27.3 ft-lb)

2) After bleeding air from the operating cylinder,

ensure that the clutch operates properly.

<Ref. to CL-26, Clutch Fluid Air Bleeding.>

C: DISASSEMBLY

CAUTION:

Do not disassemble the STI model.

1) Remove the boot and push rod.

2) Apply compressed air through clutch hose at-

tachment hole.
NOTE:

Face the piston hole down and place a piece of

wood underneath to prevent the piston from pop-

ping out.

(A) Mark
(B) Clutch hose

(C) Operating cylinder

T2

T1

CL-00421

CL-00802

(A)

(B)

(C)

(A) Clutch hose
(B) Operating cylinder

(C) Mark

CL-00709

T1

T2

T2

CL-00743

(A)

(B)

(C)

CL-00716

CL-21

Operating Cylinder

CLUTCH SYSTEM

3) Separate the piston and piston spring.

D: ASSEMBLY

NOTE:

During assembly, apply hydraulic oil to all parts.
Recommended clutch fluid:

New FMVSS No. 116 DOT3 or DOT4

1) Install the piston spring onto the piston.

2) Insert piston into the operating cylinder.

3) Install push rod to the boot.

4) Install boot and push rod to the operating cylin-

der.

E: INSPECTION

1) Check that the operating cylinder is not dam-

aged. If operating cylinder is damaged, replace it.

2) Check the operating cylinder for fluid leakage or

damage on the boot. Replace the operating cylin-

der if leaks or damages are noted.

CL-00717

CL-00717

CL-00716

CL-22

Master Cylinder

CLUTCH SYSTEM

6. Master Cylinder

A: REMOVAL

1) Disconnect the ground cable from battery.

2) Thoroughly drain the clutch fluid from the reser-

voir tank.

3) Remove the instrument panel lower cover. <Ref.

to EI-49, REMOVAL, Instrument Panel Lower Cov-

er.>

4) Remove the snap pin and clevis pin, and then

separate the push rod of the master cylinder from

clutch pedal.

5) Remove the intercooler. <Ref. to IN(STI)-12,

REMOVAL, Intercooler.> <Ref. to IN(w/o STI)-12,

REMOVAL, Intercooler.>

6) Remove the clutch pipe from the master cylin-

der.

7) Remove the master cylinder and reservoir tank

as a unit.
CAUTION:

Be careful not to spill the brake fluid. Brake flu-

id spilled on the vehicle body will harm the

paint surface; wash it off with water and wipe

clean quickly if spilled.

B: INSTALLATION

1) Install the master cylinder to the vehicle body,

and connect the clutch pipe to the master cylinder.
Tightening torque:

T1: 15 N·m (1.5 kgf-m, 11.1 ft-lb)

T2: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

2) Connect the push rod of the master cylinder to

the clutch pedal, and install the clevis pin and snap

pin.
CAUTION:

Always use a new clevis pin.
NOTE:

Apply grease to the clevis pin.

3) Refill the reservoir tank with recommended

clutch fluid.

4) After bleeding air from the clutch system, ensure

that the clutch operates properly.

<Ref. to CL-26, Clutch Fluid Air Bleeding.>

5) Install the intercooler. <Ref. to IN(STI)-13, IN-

STALLATION, Intercooler.> <Ref. to IN(w/o STI)-

12, INSTALLATION, Intercooler.>

6) Connect the battery ground terminal.

(A) Clevis pin
(B) Snap pin

(C) Push rod
(D) Lock nut

(A) Master cylinder
(B) Clutch pipe

CL-00042

(A)

(B)

(C)

(D)

CL-00152

(A)

(B)

(A) Clevis pin
(B) Snap pin

(C) Push rod

CL-00561

T1

T2

CL-00045

(A)

(B)

(C)