Removal and Replacement

Master Cylinder Replacement

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 Brake Fluid Effects on Paint and Electrical Components Caution.

1. Turn the ignition switch to the OFF position.

2. Apply and release the brake pedal several times until the brake pedal becomes firm to deplete the power vacuum brake booster vacuum reserve.

3. Using a suitable tool, remove and properly dispose of the brake fluid from the master cylinder reservoir.

4. Without draining the coolant and without disconnecting the hoses, remove and position aside the radiator surge tank. Refer to Radiator Surge Tank Replacement Radiator Surge Tank Replacement.

5. Disconnect the brake fluid level indicator switch electrical connector.





6. Disconnect the master cylinder primary brake pipe fitting (1).

7. Cap the brake pipe fitting to prevent brake fluid loss and contamination.

8. Disconnect the master cylinder secondary brake pipe fitting (2).

9. Cap the brake pipe fitting to prevent brake fluid loss and contamination.

10. If equipped with electronic power steering, remove the bolt and position aside the power steering wiring harness and bracket assembly.





11. Remove the master cylinder nuts (1).





12. Remove the master cylinder (1).

13. Remove the master cylinder O-ring seal (2).

Installation Procedure

1. If installing a new master cylinder, bench bleed the master cylinder. Refer to Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding.





Note:
Ensure the O-ring seal is properly seated in the groove in the master cylinder body and is not distorted.

2. Install the master cylinder (1) and master cylinder O-ring seal (2).





Caution:
Refer to Fastener Caution Fastener Caution.

3. Install the master cylinder nuts (1) and tighten to 50 Nm (37 lb ft).

4. Position the power steering wiring harness and bracket assembly to the master cylinder body, if equipped.

5. If equipped with electronic power steering, install the power steering wiring harness bracket bolt and tighten to 9 Nm (80 lb in)





6. Connect the master cylinder primary brake pipe fitting (1) and tighten to 25 Nm (18 lb ft).

7. Connect the master cylinder secondary brake pipe fitting (2) and tighten to 25 Nm (18 lb ft).

8. Connect the brake fluid level indicator switch electrical connector.

9. Install the radiator surge tank. Refer to Radiator Surge Tank Replacement Radiator Surge Tank Replacement.

10. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Manual)Hydraulic Brake System Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure).