Brake Master Cylinder: Service and Repair
MASTER CYLINDER
COMPONENTS
REMOVAL
1. Detach the brake tubes from the master cylinder and drain the brake fluid into container, and then install the plug.
CAUTION: Do not allow brake fluid to remain on a painted surface. Wash it off immediately.
2. Remove the master cylinder mounting nuts and then remove the master cylinder.
DISASSEMBLY
1. Remove the reservoir cap and drain the brake fluid into a suitable container.
2. Remove the fluid level sensor.
3. Remove the reservoir from the master cylinder.
4. Remove the pin with the primary piston pushed completely using a screwdriver. Remove the primary piston assembly.
5. Remove the pin with the secondary piston pushed completely using a screwdriver. Remove the secondary piston assembly.
NOTE: Do not disassemble the primary and secondary piston assembly.
6. Remove the pressure sensor (ESP).
INSPECTION
1. Check the master cylinder bore for rust or scratch.
2. Check the master cylinder for wear or damage. If necessary, clean or replace the cylinder.
CAUTION:
^ If the cylinder bore is damaged, replace the master cylinder assembly.
^ Wash the contaminated parts in alcohol.
REASSEMBLY
1. Apply genuine brake fluid to the rubber parts of the cylinder kit and grommets.
2. Carefully insert the springs and pistons in the proper direction.
3. Press the piston with a screwdriver and install the cylinder pin.
4. Install the pressure sensor (ESP).
Tightening torque: 26 - 30 Nm (2.6 - 3.0 kg-m, 19 - 21 ft. lbs.)
5. Mount two grommets.
6. Install the reservoir on the cylinder.
Tightening torque: 1.5 - 3.0 Nm (0.15 - 0.30 kg-m, 1.0 - 2.1 ft. lbs.)
INSTALLATION
1. Install the master cylinder on the brake booster with 2 nuts.
Tightening torque: 8 - 12 Nm (80 - 120 kg cm, 5.8 - 8.6 ft. lbs.)
2. Connect 2 brake tubes and the brake fluid level sensor connector.
Tightening torque (Brake tube flare nut: M10): 13 - 17 Nm (130 - 170 kg cm, 9.5-12.3 ft. lbs.)
Brake tube flare nut: M12 (ESP): 19 - 23 Nm (190 - 230 kg-cm, 13 - 16 ft. lbs.)