Without ABS

WITHOUT ABS






NOTE: The proportioning valves are not identical and cannot be interchanged. The proportioning valve that threads into the primary port (3) has M10 x 1 threads going into the master cylinder (1). The proportioning valve that threads into the secondary port (2) has M12 x 1 threads going into the master cylinder (1).

1. If removed, install the proportioning valves (2, 3) 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 seal (2) MUST be installed on the master cylinder mounting flange (1).

4. If the master cylinder does not have a new vacuum seal (2) on the mounting flange (1), remove it. Install a NEW vacuum seal on the master cylinder mounting flange making sure the seal fits squarely in its groove.

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, 2) to the master cylinder. Tighten the tube nuts to 17 Nm (150 in. lbs.).





11. Connect the wiring harness connector (1) to the brake fluid level switch (2).






WARNING: A reservoir blocker must be installed on the master cylinder brake fluid reservoir. Failure to install the reservoir blocker can result in fire in the event of an accident, resulting in serious or fatal injury.






12. If not present, a reservoir blocker (1) must be installed on the fluid reservoir (2). The blocker can be removed from the original reservoir by releasing the retaining tab (3) and opening the blocker. To install the blocker, encircle the reservoir neck with the blocker, close the blocker, snapping the retaining tab into place. Make sure the blocker is securely latched.
13. Connect the negative (ground) cable on the battery.
14. Fill the master cylinder reservoir to the proper level.

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. Service and Repair

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