Removal and Replacement

Master Cylinder Replacement
Warning: Refer to Brake Fluid Irritant Warning (Brake Fluid Irritant Warning).


Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (Brake Fluid Effects on Paint and Electrical Components Caution).

Removal Procedure

1. Without disconnecting the hoses, position the radiator surge tank aside. Refer to Radiator Surge Tank Replacement (Radiator Surge Tank Replacement).




2. Deplete the vacuum from the vacuum brake booster by removing the vacuum check valve (1) from the vacuum brake booster grommet (4). Do not disconnect the vacuum check valve (1) from the vacuum brake hose (3).
3. Disconnect the electrical connector from the brake fluid level sensor.




4. Disconnect the brake pipes from the master cylinder.





Note: Cap the exposed brake pipe fitting to prevent brake fluid loss and contamination.

5. Plug the master cylinder outlet ports.
6. Remove the 2 master cylinder mounting nuts.
7. Remove the master cylinder.
8. Inspect the master cylinder-to-vacuum brake booster seal. Replace the seal if it is damaged.
9. If replacing the master cylinder, remove the master cylinder reservoir. Refer to Master Cylinder Reservoir Replacement (Service and Repair).

Installation Procedure

1. If removed, install the master cylinder reservoir. Refer to Master Cylinder Reservoir Replacement (Service and Repair).
2. Bench bleed the master cylinder. Refer to Master Cylinder Bench Bleeding (Master Cylinder Bench Bleeding).
3. Check to ensure that the master cylinder-to-vacuum brake booster seal is properly seated on the master cylinder barrel.




4. Install the master cylinder to the vacuum brake booster.

Caution: Refer to Fastener Caution (Fastener Caution).

5. Install the 2 brake master cylinder mounting nuts and tighten to 25 Nm (18 lb ft).




6. Install the brake pipes to the master cylinder and tighten the brake pipe fittings to 32 Nm (24 lb ft).
7. Connect the electrical connector to the brake fluid level sensor.




8. Connect the vacuum brake booster check valve (1) to the vacuum brake booster grommet (4).
9. Position the radiator surge tank to the bracket. Refer to Radiator Surge Tank Replacement (Radiator Surge Tank Replacement).
10. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Hydraulic Brake System Bleeding).