Brake Master Cylinder: Service and Repair

MASTER CYLINDER





COMPONENT

REMOVAL





1. Disconnect the low fluid level sensor wiring connector.





2. Disconnect the brake pipes from the master cylinder and ABS control unit by using SST (OK130 430 019). Cap the tubes and plug the master cylinder ports and ABS control unit ports to prevent the entry of contaminants.





3. Remove the two master cylinder attaching nuts and washers.
4. Remove the master cylinder from the mounting studs on the brake booster.

INSTALLATION
1. Position the master cylinder on the brake booster. Refer to check push rod length.
Piston to push rod clearance Standard type





a. Place the SST on the master cylinder. Turn the adjusting bolt until it bottoms in the push rod hole in the piston.
b. Apply 19.7 inHg (500 mmHg) vacuum to the power brake unit with a vacuum pump.
c. Invert the adjustment gauge used in Step 1 and place it on the power brake unit.





d. Measure the clearance between the end of the gauge and the push rod of the power brake unit. If it is not 0 inch (0 mm), loosen the push rod locknut and turn the push rod to make the adjustment.








NOTE: By making the above adjustment, the clearance between the push rod and piston (after installation of the brake master cylinder to the power brake unit) will be as shown in the displayed table.





2. Install the master cylinder attaching washers and nuts. Tighten the master cylinder attaching nuts.
Tightening torque: 9.81 - 15.7 Nm (1.0 - 1.6 kg-m, 7 - 12 ft. lbs.)
3. Tighten the brake pipe flare nut with the SST.
Tightening torque: 13 - 22 Nm (1.3 - 2.2 kg-m, 10 - 16 ft. lbs.)
4. Connect the low fluid level sensor wiring.
5. Bleed the brakes.