Contents: Removal 🠛 Installation 🠛
Note: Before you begin, see: Warning given at the beginning Chapter 6.
Removal
1. Remove the master cylinder reservoir cap by disconnecting the sensor wiring connector and pump out the brake fluid from the reservoir. Alternatively, open any convenient pair of bleed nipples (one in each circuit) and gently press the brake pedal several times to drain the fluid (see Chapter 6).
Note: Do not suck out the liquid by mouth as it is poisonous; use a syringe or an old rubber bulb.
2. Remove the reservoir from the master cylinder by pulling it upwards.
3. Wipe the area around the brake pipe connectors on the wall of the master cylinder and place a rag under the connectors to catch any remaining fluid. Mark the location of the couplings, then unscrew the coupling nuts and carefully remove the tubes. Cap the ends of the lines and the master cylinder openings to minimize brake fluid loss and prevent dirt from entering the system. Rinse any spilled liquid from the components with cold water.
4. Loosen and remove the two nuts securing the master cylinder to the booster unit, then remove the cylinder from the engine compartment. Remove the O-ring from the rear of the master cylinder - it needs to be replaced.
5. The master cylinder seals and internal components, unlike the reservoir mounting seals, are not sold separately, so if they are damaged, replace the cylinder assembly. The O-ring installed between the master cylinder and the vacuum booster must be replaced whenever the unit is removed.
Installation
6. Before installing the cylinder, make sure that the distance between the end of the push rod facing the master cylinder and the front of the booster is 22.3 mm (see illustration 3.9).
3.9. Adjusting the length of the booster push rod: C - Push rod fork; L - 110 mm; R - Push rod nut; X - 22.3 mm.
If necessary, adjust this distance using the "P" nut.
7. Clean all dirt from the mating surfaces of the master cylinder and booster. Install the new O-ring into the groove on the master cylinder.
8. Install the master cylinder onto the booster, ensuring that the push rod enters the cylinder centered. Install the master cylinder mounting nuts and tighten them to the torque specified in the Specifications.
9. Wipe the brake pipe connectors clean, then install them onto the master cylinder ports. Tighten the union nuts to the torque specified in the Specifications.
10. Carefully align the tank with the mounting seals and push it into the working position.
11. Fill the master cylinder reservoir with new fluid and bleed the brake hydraulic system as described in Chapter 6.