Brake Master Cylinder: Service and Repair

CAUTION:
^ Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is splashed on painted areas, wash it away with water immediately.
^ In the case of brake fluid leakage from the master cylinder, disassemble the cylinder. Then check piston cups for deformation or scratches and replace necessary parts.
^ Refill with new "DOT 3" brake fluid.
^ Never reuse drained brake fluid.

Master Cylinder Assembly:

REMOVAL
1. Connect a vinyl tube to air bleeder valve.
2. Drain brake fluid from each air bleeder valve, depressing brake pedal to empty fluid from master cylinder.
3. Remove brake pipe flare nuts.
4. Remove master cylinder mounting nuts.

Bending Claws Of Stopper Cap:

DISASSEMBLY
1. Bend claws of stopper cap outward.
2. Remove piston assemblies. If it is difficult to remove secondary piston assembly, gradually apply compressed air through fluid outlet.
3. Draw out reservoir tank.

Inserting Secondary And Primary Piston Assemblies:

ASSEMBLY
1. Insert secondary piston assembly. Then insert primary piston assembly.
^ Pay attention to direction of piston cups. Also, insert pistons squarely to avoid scratches on cylinder bore.

Installing Stopper Cap And Reservoir Tank:

2. Before installing stopper cap, ensure that claws are bent inward.
3. Push reservoir tank seals into cylinder body.
4. Push reservoir tank into cylinder body.

INSTALLATION
1. Place master cylinder onto brake booster and secure mounting nuts lightly.
2. Torque mounting nuts to 12 - 15 Nm (9 - 11 ft. lbs.)

CAUTION:
^ Refill with new "DOT 3" brake fluid.
^ Never reuse drained brake fluid.

3. Fill up reservoir tank with new brake fluid.
4. Plug all ports on master cylinder with fingers to prevent air suction while releasing brake pedal.
5. Have driver slowly depress brake pedal slowly several times until no air comes out of master cylinder.
6. Fit brake lines to master cylinder and torque to 15 - 18 Nm (13 - 15 ft. lb.)
7. Bleed air from each caliper. Service and Repair