Master Cylinder - Without ABS

MASTER CYLINDER - WITHOUT ABS

NOTE: The proportioning valves are not identical and cannot be interchanged. The proportioning valve that threads into the primary port has 7/16 in.-24 threads in its outlet port. The proportioning valve that threads into the secondary port has 3/8 in.-24 threads in its outlet port.

1. If removed, install the proportioning valves in their master cylinder ports. Tighten the proportioning valves to 30 Nm (22 ft. lbs.).

NOTE: The master cylinder must be bled before installing it on the vehicle.

2. Bench bleed the master cylinder. Procedures
3. Wipe the face of the power brake booster clean where the master cylinder seal comes in contact when it's installed. Do not get any cleaner or debris inside the booster.




CAUTION: When installing a master cylinder on the vehicle, a NEW vacuum O-ring seal (2) MUST be installed on the master cylinder mounting flange (1).

4. If the master cylinder does not have a new vacuum O-ring seal (2) on the mounting flange (1), remove it. Install a NEW vacuum O-ring seal on the master cylinder mounting flange making sure the O-ring fits evenly against the mounting flange.

CAUTION: If resistance is met during master cylinder insertion into power brake booster, the master cylinder push rod may not be lined up with the booster push rod. Remove the master cylinder, realign and insert it again.

5. Line the master cylinder mounting holes up with the mounting studs on the power brake booster. Ensure the master cylinder piston push rod lines up with the booster push rod, then carefully slide the master cylinder into the power brake booster until it contacts the face of the booster.




6. Install two NEW master cylinder mounting nuts (3). Tighten each nut to 25 Nm (18 ft. lbs.).




7. If equipped with a manual transaxle and a new reservoir is being installed, using an appropriate cutting tool, cut the clutch actuator port at the center of the "V" groove (2) opening the hydraulic clutch port (1). Discard the severed plug (3).




8. If equipped with a manual transaxle, slide the clutch actuator hose (2) onto the reservoir port (1). Install the hose clamp just past the upset bead on the port.




9. Connect the two rear brake tubes (1, 2) to the proportioning valves on the master cylinder (3). Tighten the tube nuts to 17 Nm (150 in. lbs.).




10. Connect the two front brake tubes (1, 3) to the master cylinder (2). Tighten the tube nuts to 17 Nm (150 in. lbs.).




11. Connect the wiring harness connector (1) to the brake fluid level switch (2).
12. Connect the negative (ground) cable on the battery.
13. Fill the master cylinder reservoir to the proper level. Service and Repair

WARNING: Be certain a firm brake pedal is achieved prior to attempting to operate the vehicle. If a firm brake pedal cannot be achieved, bleed the brake hydraulic system and check for leaks. Brake Bleeding

14. Road test the vehicle to ensure proper operation of the brakes.