Brake Master Cylinder: Service and Repair

MASTER CYLINDER

COMPONENTS:

REMOVAL





NOTE: Do not spill brake fluid on the vehicle; it may damage if brake fluid does contact the paint, wash it the paint, off immediately with water

1. Remove air cleaner assembly (A).





2. Disconnect the brake fluid level switch connector (A), and remove the reservoir cap (B).
3. Remove the brake fluid from the master cylinder reservoir (C) with a syringe.





4. Disconnect the brake lines (A) from the master cylinder. To prevent spills, cover the hose joints with rags or shop towels.
5. Remove the master cylinder mounting nuts (B) and washers.
6. Remove the master cylinder (C) from the brake booster. Be careful not to bend or damage the brake lines when removing the master cylinder.

INSTALLATION
1. Install the master cylinder to the brake booster.





2. Connect the brake tubes (A) and brake level switch connector (B) to the master cylinder.
3. After refilling the master cylinder reservoir to the maximum line, bleed the brake system.

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 (B) from the master cylinder after remove the mounting screw (A).





4. Remove the proportioning valves. (Conventional brake system)





5. Remove the retainer ring (A) by using the snap ring pliers.
6. Remove the primary piston assembly (A).





7. Remove the pin (C) with the secondary piston (B) pushed completely using a screwdriver. Remove the secondary piston assembly (B).

NOTE: Do not disassemble the primary and secondary piston assembly.

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 (A) with a screwdriver and install the cylinder pin (B).





4. Press the piston with a screwdriver and install the retainer ring.
5. Install the proportioning valves (in case of CBS).
6. Mount two grommets.
7. Install the reservoir on the cylinder.