Master Cylinder Reservoir Replacement

Master Cylinder Reservoir Replacement

Disassembly Procedure

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).

Note: Hold the master cylinder with the piston facing upward in order to prevent the piston from sliding out. The piston is not serviced separately from the master cylinder.

1. Remove the master cylinder from the vehicle. Refer to Master Cylinder Replacement (1.8L Engine) (Master Cylinder Replacement)Master Cylinder Replacement (2.4L Engine) (Master Cylinder Replacement).




2. Remove the cap (1).
3. Remove the filter (2).

Caution: Do not clamp on the master cylinder body. Doing so may damage the master cylinder.

4. Place the master cylinder in a vise.




5. Using a pin punch and a hammer, tap out the straight pin and remove the reservoir (1) from the master cylinder.
6. Remove the 2 grommets from the master cylinder.
Discard the grommets.

Assembly Procedure




1. Apply lithium soap base glycol grease to 2 NEW grommets (5).
2. Install the 2 grommets to the master cylinder.




3. If the vehicle has a manual transmission and you are installing a NEW reservoir, cut off the clutch tube tip from the reservoir. Ensure the fluid supply is not hindered by the cut.

The clutch tube length (a) is 22-24 mm (0.866-0.945 in).




4. With the master cylinder in a vise, install the reservoir (1) to the master cylinder.
5. Using a pin punch and a hammer, tap in the straight pin.
6. Remove the master cylinder from the vise.
Warning: Refer to Brake Fluid Warning (Dangers, Warnings, and Cautions).


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

7. Bleed the master cylinder. Refer to Master Cylinder Bench Bleeding (Master Cylinder Bench Bleeding).
8. Install the filter.
9. Install the cap.
10. Install the master cylinder to the vehicle. Refer to Master Cylinder Replacement (1.8L Engine) (Master Cylinder Replacement)Master Cylinder Replacement (2.4L Engine) (Master Cylinder Replacement).