Brake Master Cylinder: Service and Repair

REMOVAL

Exploded View Of Master Cylinder (W/O ABS):

CAUTION:
^ Be careful not to bend or damage the brake pipes when removing the master cylinder.
^ Do not spill brake fluid on the car; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.
^ To prevent spills, cover the hose joints with rags or shop towels.

1. Remove the reservoir cap from the master cylinder.
2. The brake fluid may be sucked out through the top of the master cylinder reservoir.
3. Disconnect the brake pipes from the master cylinder.
4. Remove the master cylinder mounting nuts and the master cylinder from the brake booster.


INSPECTION/DISASSEMBLY

Master Cylinder Inspection/Disassembly:

CAUTION:
^ Do not spill brake fluid on the car, it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.
^ Before reassembling, check that all parts are free of dust and other foreign particles.
^ Do not try to disassemble the master cylinder assembly. Replace the master cylinder assembly with a new assembly if necessary.
^ Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.


INSTALLATION

Master Cylinder Installation:

CAUTION:
^ Do not spill brake fluid on the car; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.
^ Do not mix different brands of brake fluid as they may not be compatible.
^ Do not reuse the drained fluid. Use only clean DOT 3 or 4 brake fluid.
^ When connecting the brake pipes, make sure that there is no interference between the brake pipes and other parts.
^ Be careful not to bend or damage the brake pipes when installing the master cylinder.

NOTE: Before installing the master cylinder, check and adjust the pushrod clearance, refer to Brakes and Traction Control/Brakes/Hydraulic System/Brake Booster/Vacuum Brake Booster/Adjustments.

1. Install the master cylinder on the brake booster with master cylinder mounting nuts.
2. Connect the brake pipes to the master cylinder.
3. Fill the master cylinder reservoir up and bleed the brake system, refer to Brakes and Traction Control/Brakes/Service and Repair.
4. Install the reservoir cap.
5. After installation, perform the following inspections and adjust if necessary.
^ Brake pedal height, refer to Brakes and Traction Control/Brakes/Hydraulic System/Brake Pedal Assy/Adjustments.
^ Brake pedal free play, refer to Adjustments / Pedal Height.