Master Cylinder - Installation

INSTALLATION

NOTE: The master cylinder must be bled before installing it on the vehicle.

1. Bench bleed the master cylinder. Procedures
2. Wipe the face of the power brake booster clean where the vacuum seal on the rear of the master cylinder 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).

3. 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.




4. Position master cylinder (1) on studs of power brake booster (2), aligning booster push rod with master cylinder piston.
5. Install two master cylinder mounting nuts (3). Tighten both mounting nuts to 25 Nm (225 in. lbs.).

CAUTION: When tightening primary and secondary brake tube nuts at master cylinder, be sure brake tubes do not contact any other components within vehicle and that there is slack in flexible sections of tubes. This is required due to movement between ABS ICU and master cylinder while vehicle is in motion.





6. Thread primary (2) and secondary (3) brake tubes into master cylinder primary and secondary ports. Brake tubes must be held securely when tightened to control orientation of flex section. Tighten tube nuts to 14 Nm (120 in. lbs.).




7. Connect wiring harness connector (2) to brake fluid level switch (1) mounted in brake fluid reservoir.
8. Place coolant recovery bottle in its normal mounted position. Install upper and tighten all nuts fastening it in place. Coolant Recovery Container - Installation
9. Connect negative battery cable to battery post.
10. Fill the master cylinder reservoir to the proper level. Service and Repair

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. Brake Bleeding

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