Brake Master Cylinder Assembly Overview

Brake Master Cylinder Assembly Overview

• Master brake cylinders can no longer be disassembled, servicing is not possible.

• Use only new brake fluid. Observe information on brake fluid reservoir!





1 - Brake fluid reservoir

• Screen in brake fluid reservoir must not be removed.

2 - Sealing cap with seal

3 - Dowel bolt, 10 Nm

4 - Wiring to master cylinder

5 - Tandem brake booster

• Adjusting ball head => [ Adjusting ball head ]

• Function test: With engine switched off, depress brake pedal firmly several times (to deplete vacuum in tool).

• Depress and hold brake pedal with average foot pressure and start engine. If brake booster is working properly, pedal will be felt to give noticeably under foot (booster assistance becomes effective).

• with adhesive seal

• If malfunctioning: replace as complete unit.

• Removing and installing, refer to => [ Brake Booster ] Service and Repair

6 - Torx flange bolt, 25 Nm

7 - Mounting bracket for pedal assembly

• Removing and installing, refer to=> [ Brake Pedal Mounting Bracket ] Brake Pedal Mounting Bracket

8 - Sleeves

9 - Bolts (Torx 45), 23 Nm

10 - Self-locking hex nut, 49 Nm

11 - Brake line, 16 Nm

• Master brake cylinder/secondary piston circuit to hydraulic unit

12 - Brake line, 16 Nm

• Master brake cylinder/primary piston circuit to hydraulic control unit

13 - Seal

• Replace

14 - Dual master brake cylinder

• Cannot be serviced. Replace as complete unit if malfunctioning.

• Removing and installing, refer to => [ Brake Master Cylinder ] Brake Master Cylinder

15 - Sealing plugs

• Moisten with brake fluid and press into brake fluid reservoir

16 - Vacuum hose with ear hose clamp

• Insert into brake booster

17 - Sealing plugs

• Connection for vacuum hose

• Use only new brake fluid. Observe information on brake fluid reservoir!

Adjusting ball head





Left-hand drive vehicles:

- a = 178.2 mm ± 0.5mm -

Right-hand drive vehicles:

- a = 203.3 mm ± 0.5mm -

• Surface - 1 - for measuring.

• When measuring the ball head, it must be set at right angles to the surface of the brake booster.

• Measure to end of ball head without gasket installed.

• Each time push rod adjustment in vehicle is changed, brake light switch must be replaced.