Master Cylinder

Removal

CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used.

CAUTION: Remove brake fluid spillage immediately from paint work, with clean water.

1. Position vehicle on a four-post lift.

2. Open engine compartment and fit paint work protection covers to fenders.

3. Disconnect battery ground cable.

4. Remove windshield wiper arm and blade assembly for access.

5. Remove plenum cover for access.

6. Remove pedal housing, brake booster and master cylinder assembly.





7. Remove nuts securing master cylinder to brake booster.





8. Remove master cylinder from brake booster.
- Remove master cylinder.
- Remove and discard seal.
- Remove filler cap and empty residual brake fluid into a container.





9. Remove fluid reservoir from master cylinder.
- Remove locating pin.
- Pull reservoir from master cylinder.





10. Install plugs into reservoir ports.





11. Remove and discard seals from master cylinder.





12. Install plugs into master cylinder ports.

13. Clean components and mating surfaces.

Installation





1. Install seals into master cylinder.
- Remove plugs.
- Lubricate seals with clean brake fluid.
- Install seals.





2. Install fluid reservoir to master cylinder.
- Remove plugs from reservoir.
- Install reservoir, making sure reservoir is fully seated.
- Install locating pin.





3. Install master cylinder to brake booster.
- Install seal.
- Install master cylinder, make sure master cylinder rod locates brake booster rod.





4. Install and tighten nuts to 21-29 Nm.

5. Install pedal housing, brake booster and master cylinder assembly.

6. Install plenum cover.

7. Install windshield wiper arm and blade assembly.

8. Connect battery ground cable.

9. Bleed brake system.

10. Remove paint-work protection covers and close engine compartment.