Master Cylinder

NOTE:
^ Numbers in parentheses ( ) below refer to numbers in each illustration.
^ This unit comprises the master cylinder, power brake hydraulic booster unit and the Anti-Lock Brake System (ABS) hydraulic assembly.

REMOVAL
1. Switch off ignition.
2. Operate the brake pedal 30 times. Pedal travel will increase slightly and reduced resistance will be felt as pressure decreases.
3. Wait for 60 seconds, press the brake pedal four more times. This procedure will ensure that all pressure is evacuated from the system.

WARNING: Before bleeding the system or working on any component in the brake system, the preceding steps MUST be carried out to depressurize the accumulator.

4. Position cloth under assembly to collect fluid spillage.
5. Release clip from fluid reservoir hose (6) at pump.
6. Disconnect hose and allow fluid to drain into suitable container.
7. Discard fluid, then plug hose and pump.
8. Disconnect hose from reservoir (8). Plug hose and reservoir. On manual transmission models, reposition container below clutch master cylinder feed hose, then disconnect clutch hose from reservoir. Allow fluid to drain, then plug hose and reservoir.
9. Disconnect 2 multiplugs (11) from booster.
10. Disconnect fluid level switch multiplug (12).
11. Remove banjo bolt securing high pressure hose to pump (13). Discard sealing washers. Plug hose and pump.
12. Unscrew brake line pipe unions (14) from booster. Plug pipes and booster.

NOTE: Mark brake lines as necessary for later assembly.





13. Remove left underdash trim panel (2).





14. Release booster push rod (16) from brake pedal.





15. Remove 2 bolts (17) securing booster assembly to pedal box. Remove booster.





16. Remove banjo bolt securing high pressure hose to booster. Discard sealing washers (18). Plug hose and booster.

INSTALLATION
1. Remove plugs from high pressure hose and booster.
2. Position high pressure hose to booster. Secure with banjo bolt and new sealing washers. Tighten to 24 Nm (18 ft. lbs.).
3. Position booster to pedal box. Ensure push rod engages with pedal. Secure booster with bolts. Tighten to 45 Nm (33 ft. lbs.).
4. Remove plugs from brake pipes and booster. Align pipes to booster. Secure union nuts. Tighten to 14 Nm (10 ft. lbs.).
5. Remove plugs from high pressure hose and pump.
6. Position high pressure hose to pump. Secure with banjo bolt and new sealing washers. Tighten to 24 Nm (18 ft. lbs.).
7. Connect fluid level switch multiplug (12).
8. Connect 2 multiplugs (11) to booster.
9. Remove plugs from reservoir, brake fluid hose and pump.
10. Position hose to reservoir and pump (6). Secure with new clips.
11. Remove cloth from under booster.
12. Reconnect battery negative lead.
13. Bleed braking system. Brake Bleeding
14. Install left underdash trim panel.