Removal
1. Disconnect the electrical connector from the brake fluid level sensor.
2. Disconnect the brake pipes from the master cylinder and close the open holes with suitable plugs.
Warning! Brake fluid dissolves paint, plastic and wire insulation, so if the fluid accidentally comes into contact with the vehicle's paintwork or components, rinse them with plenty of water.
3. Loosen the master brake cylinder mounting nuts and remove the master brake cylinder. Tightening torque: 8–12 Nm.
Disassembly
1. Remove the plug and drain the brake fluid from the reservoir.
2. Remove the screws and, using a screwdriver as a lever, remove the reservoir from the master cylinder.
3. Remove the retaining ring.
4. Use a screwdriver to press the primary piston, remove the cylindrical pin and remove the primary piston.
5. Use a screwdriver to press the secondary piston, remove the cylindrical pin and remove the secondary piston.
Caution: Do not disassemble the primary and secondary pistons.
Examination
1. Check the inner surface of the master cylinder housing for rust and wear.
2. Check the master cylinder for wear or damage. Clean or replace the master cylinder if necessary.
- 1. If the master cylinder housing bore is damaged, replace the master cylinder assembly.
- 2. To remove dirt, clean the master cylinder body with isopropyl alcohol.
Assembly
1. Lubricate the inside surface of the master cylinder and the outside surfaces of the primary and secondary pistons with the recommended brake fluid.
2. Carefully insert the two springs and pistons into the master cylinder bore.
3. Press the pistons and install the retaining ring.
4. Use a screwdriver to press down on the piston and install the cylindrical pin.
5. Install two sealing rings.
6. Firmly insert the reservoir into the sealing rings of the master cylinder.
Installation
1. Install the brake master cylinder to the brake booster.
2. Install the brake master cylinder and brake booster to the engine compartment bulkhead.
3. Connect the brake pipes to the brake master cylinder.
4. Connect the vacuum hose to the brake booster.
5. Connect the rod to the brake pedal and install the pin with a head and a hole for the cotter pin and secure it with a new spring cotter pin.
6. Fill the brake fluid and bleed air from the hydraulic circuit of the brake system.
Warning! Do not attempt to repair the brake booster as it is a non-separable type.