Master Cylinder Replacement

Master Cylinder Replacement (2.4L Engine)

Special Tools

J-37767 - Brake Booster Piston Rod Adjuster

Removal Procedure

1. With the engine OFF, press the brake pedal several times in order to remove the vacuum from the brake booster.




2. Slide the hood rear seal (1) to the right and up in order to disengage the clip.




3. Disengage the 5 claws (1) and remove the left side access panel.




4. Remove the 2 nuts (1, 2).
5. Remove the damper and the tie bar.




6. Remove the 2 nuts (1, 2) and the engine cover.




7. Disconnect the mass air flow meter connector (1).
8. Separate the 2 wire harness clamps (2, 3).




9. Disconnect the vacuum switching valve connector (3).
10. Loosen the 2 hose clamps (1, 2) and disconnect the vacuum hose.




11. Loosen the hose clamp (1) and disconnect the ventilation hose.




12. Unlock the 3 air cleaner case clamps (2, 3, 4).
13. Loosen the air cleaner hose clamp (1).
14. Remove the upper portion of the air cleaner case with the hose.
15. Cover the air cleaner filter element in order to protect the filter from spills.
Warning: Refer to Brake Fluid Irritant Warning (Brake Fluid Irritant Warning).


Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (Vehicle Damage Warnings).

16. Remove the cap from the brake fluid reservoir.
17. Remove the filter from the reservoir.
18. Siphon the brake fluid from the reservoir.




19. If the vehicle has a manual transmission, loosen the clamp and remove the clutch tube (1) from the reservoir.




20. Disconnect the connector (1) from the brake fluid level sensor.
21. Disengage the clamp from the brake fluid level sensor wire.




22. Remove the 2 brake pipes (2) from the master cylinder (4).
23. Remove the 2 brake pipes (6) from the 2-way fitting (5).
24. Remove the 2 nuts (1) from the 2-way fitting.
25. Remove the 2-way fitting from the master cylinder.

Note: Hold the master cylinder with the piston facing upward in order to prevent the piston from sliding out.

26. Remove the master cylinder with the reservoir from the vacuum brake booster.
27. Remove the seal (3) from the master cylinder.
28. Remove the reservoir and the grommets from the master cylinder. Refer to Master Cylinder Reservoir Replacement (Master Cylinder Reservoir Replacement).

Inspection Procedure





Note: The accessory tool comes with a new master cylinder. If you are installing a new master cylinder, inspect the master cylinder piston-to-vacuum brake booster push rod clearance. If you are reusing the original master cylinder, an inspection is not necessary, even with a new brake booster.

1. Apply chalk to the tip of the accessory tool (1).
2. Measure the clearance between the brake booster push rod and the accessory tool.
If there is a clearance between the accessory tool and the shell of the brake booster, the brake booster push rod is protruding too far.
If the chalk does not stick to the tip of the brake booster push rod, the brake booster push rod is not protruding far enough.
3. If the clearance between the brake booster push rod and the accessory tool is not correct, adjust the length of the brake booster push rod.

Adjustment Procedure





Hold the brake booster push rod with the J-37767 - Adjuster (1) and turn the tip of the rod with a socket driver in order to adjust the length of the rod.

Installation Procedure

1. Install the reservoir and the grommets to the master cylinder. Refer to Master Cylinder Reservoir Replacement (Master Cylinder Reservoir Replacement).
2. Bench bleed the master cylinder. Refer to Master Cylinder Bench Bleeding (Master Cylinder Bench Bleeding).




3. Install the seal (3) to the master cylinder (4).
4. Ensure the master cylinder piston is covered with lithium soap base glycol grease, not dirt or any foreign objects.
5. Install the master cylinder to the vacuum brake booster.
6. Install the 2-way fitting (5) to the master cylinder.

Caution: Refer to Fastener Caution (Fastener Caution).

7. Install the 2 nuts (1) to the 2-way fitting and tighten to 13 Nm (115 lb in).
8. Install the 2 brake pipes (6) to the 2-way fitting. Using a torque wrench with a fulcrum length of 250 mm (9.84 in) and a union nut wrench, tighten the fittings to 14 Nm (124 lb in).
9. Install the 2 brake pipes (2) to the master cylinder. Using a torque wrench with a fulcrum length of 250 mm (9.84 in) and a union nut wrench, tighten the fittings to 14 Nm (124 lb in).




10. Connect the connector (1) to the brake fluid level sensor.
11. Engage the clamp on the brake fluid level sensor wire.




12. If the vehicle has a manual transmission, install the clutch tube (1) with the clamp to the reservoir.
Warning: Refer to Brake Fluid Warning (Dangers, Warnings, and Cautions).


Caution: Refer to Filling the Master Cylinder Caution (Filling the Master Cylinder Caution).

13. Fill the brake fluid reservoir. Refer to Master Cylinder Reservoir Filling (Master Cylinder Reservoir Filling).
14. If the vehicle has a manual transmission, bleed the clutch system. Refer to Hydraulic Clutch System Bleeding (Service and Repair).
15. Bleed the entire hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Service and Repair).
16. Inspect the brake system for leaks. Refer to Brake System External Leak Inspection (Brake System External Leak Inspection).
17. Remove the cover from the air cleaner filter element.




18. Install the upper portion of the air cleaner case with the hose and the hose clamp (1).
19. Lock the 3 clamps (2, 3, 4).




20. Install the ventilation hose with the hose clamp (1).




21. Install the vacuum hose with the 2 hose clamps (1, 2).
22. Install the vacuum switching valve connector (3).




23. Connect the mass air flow meter connector (1).
24. Connect the 2 wire harness clamps (2, 3).




25. Install the engine cover with the 2 nuts (1, 2) and tighten to 9 Nm (80 lb in).




26. Install the damper and the tie bar to the brackets with the 2 nuts (1, 2) and tighten to 52 Nm (38 lb ft).




27. Install the left side access panel and engage the 5 claws (1).
28. Install the hood rear seal and engage the clip.
29. Measure the brake pedal travel. Adjust the brake pedal travel if necessary. Refer to Brake Pedal Travel Measurement and Inspection (Brake Pedal Travel Measurement and Inspection).