Brake Master Cylinder: Service and Repair
Master Cylinder ReplacementNOTE: Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.
1. Remove the air cleaner assembly (A).
2. Disconnect the brake fluid level sensor connector (A).
3. Remove the clutch reservoir (B) and engine wire harness clip (C) from the master cylinder mounting base (D).
4. Remove the reservoir cap and brake fluid from the reservoir.
5. Remove the reservoir (E) on the master cylinder mounting base.
6. Disconnect the brake lines (F) from the master cylinder (G). TO prevent spills, cover the hose joints with rags or shop towels.
7. Remove the master cylinder mounting nuts (H) and washers.
8. Remove the master cylinder from the brake booster. Be careful not to bend or damage the brake lines when removing the master cylinder.
9. Remove the rod seal (I) from the master cylinder.
10. install the master cylinder in the reverse order of removal, and note these steps:
^ Replace all the rubber parts with new ones whenever the master cylinder is removed.
^ Check the pushrod clearance before installing the master coriander, airy adjust it if necessary.
^ Use a new rod seal on reassembly.
^ Coat the inner bore lip and outer circumference of the new rod seal (A) with the recommended seal grease in the Master cylinder set.
^ Install the rod steal onto the master cylinder with its grooved side (B) toward the master cylinder.
^ Check the brake pedal height and free play after installing the master cylinder, and adjust it if necessary.
^ Bleed the brake system.