Master Cylinder Replacement
Master Cylinder Replacement (With RPO HP5)
Removal 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: The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1 to 3 minutes.
1. Turn the ignition to OFF, without pausing at ACCESSORY, and remove the ignition key.
Note: During the pressure relief process, the fluid level in the master cylinder reservoir will rise. Do not remove the master cylinder reservoir cap during the pressure relief process.
2. Wait approximately 1 to 3 minutes until the brake modulator and HPA pressure relief is complete.
3. Remove the brake fluid from the brake master cylinder reservoir and discard into an approved container.
4. Remove the underhood electrical center. Refer to Underhood Electrical Center or Junction Block Replacement (HP7) (Service and Repair)Underhood Electrical Center or Junction Block Replacement (HP5) (Service and Repair).
5. Without draining the coolant or disconnecting the hoses, remove and position aside the radiator surge tank. Refer to Radiator Surge Tank Replacement (Service and Repair).
6. Disconnect the brake fluid level sensor electrical connector.
7. Disconnect the brake master cylinder reservoir supply hose quick connect (1) and position the hose aside.
8. Disconnect the brake master cylinder reservoir return hose quick connect (2) and position the hose aside.
Note: Mark the location of the brake pipes to the master cylinder to ensue correct installation.
9. Disconnect the brake master cylinder rear brake pipe fittings (1).
Cap the brake pipe fittings and plug the master cylinder outlet ports to prevent brake fluid loss and contamination.
10. Disconnect the brake master cylinder front brake pipe fittings (1).
Cap the brake pipe fittings and plug the master cylinder outlet ports to prevent brake fluid loss and contamination.
11. Disconnect the brake master cylinder primary brake pipe fitting (1).
Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination.
12. Remove the brake master cylinder nuts (1).
Discard the brake master cylinder nuts.
13. Remove the brake master cylinder (1).
14. Remove the brake master cylinder O-ring seal (2).
Installation Procedure
1. Bench bleed the master cylinder. Refer to Master Cylinder Bench Bleeding (Without RPO HP5) (Master Cylinder Bench Bleeding)Master Cylinder Bench Bleeding (With RPO HP5) (Master Cylinder Bench Bleeding).
2. Install the master cylinder O-ring seal to the master cylinder.
Ensure the master cylinder O-ring seal is fully seated to the master cylinder body.
3. Install the brake master cylinder (1) and the master cylinder O-ring seal (2).
Ensure the brake master cylinder seal is fully seated in the groove on the master cylinder housing.
Caution: Refer to Fastener Caution (Fastener Caution).
4. Install 2 new brake master cylinder nuts (1) and tighten to 25 Nm (18 lb ft).
5. Connect the brake master cylinder primary brake pipe fitting (1) and tighten to 23 Nm (17 lb ft).
Note: Install the brake pipes in the location noted during removal.
6. Connect the brake master cylinder front brake pipe fittings (1) and tighten to 23 Nm (17 lb ft).
Note: Install the brake pipes in the location noted during removal.
7. Connect the brake master cylinder rear brake pipe fittings (1) and tighten to 23 Nm (17 lb ft).
8. Connect the brake master cylinder reservoir supply hose quick connect (1).
9. Connect the brake master cylinder reservoir return hose quick connect (2).
10. Connect the brake fluid level sensor electrical connector.
11. Install the radiator surge tank. Refer to Radiator Surge Tank Replacement (Service and Repair).
12. Install the underhood electrical center. Refer to Underhood Electrical Center or Junction Block Replacement (HP7) (Service and Repair)Underhood Electrical Center or Junction Block Replacement (HP5) (Service and Repair).
13. Fill the brake master cylinder reservoir. Refer to Master Cylinder Reservoir Filling (Without RPO HP5) (Master Cylinder Reservoir Filling)Master Cylinder Reservoir Filling (With RPO HP5) (Master Cylinder Reservoir Filling).
14. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (Service and Repair)Hydraulic Brake System Bleeding (Pressure) (Service and Repair).