Removing
1. Remove the filler cap of the brake master cylinder reservoir and the fluid level sensor (refer to section Schedule of ongoing maintenance).
2. Where the reservoir is installed directly on the master cylinder, pump out the brake fluid from it using a syringe, pipette or hydrometer. If the master cylinder or reservoir needs to be replaced, remove the reservoir by simply pulling it up.
3. Where the tank is mounted away from the master cylinder, remove the nuts securing its bracket to the bulkhead, then unhook the rubber strap holding the tank to the bracket. Turn the reservoir upside down and drain the brake fluid into a suitable container. Separate the connecting hoses from the tank and remove their tips from the master cylinder by pulling them towards you.
4. Wipe the area around the brake pipe couplers on the master cylinder wall and place a rag underneath the couplers to catch the fluid. Sketch the location of the couplings, then unscrew the coupling nuts and carefully remove the tubes. Seal the ends of the pipes and bores of the master cylinder to minimize loss of brake fluid and prevent dirt from entering the system. Rinse spilled liquid with cold water.
5. Loosen and remove the nuts and washers securing the master cylinder to the vacuum booster block. Remove the master cylinder from the engine compartment along with the O-ring to be replaced.
6. It is not possible to overhaul the cylinder as its internal components are not sold separately. If at least one of the components is defective, the complete assembly of the master cylinder must be replaced. The only components that can be replaced separately are the cylinder reservoir seals and the o-ring installed between the master cylinder and the booster.
Installation
1. Before installation, check the distance between the end of the push rod and the contact surface of the amplifier (refer to section Check, removal and installation of the block of the vacuum amplifier).
2. Make sure the contact surfaces are clean and dry, then install a new O-ring on the back of the master cylinder.
3. Carefully install the main cylinder on the booster, making sure that the pusher of the booster hits the cylinder centrally, screw on the fixing nuts and tighten them to the specifications given in Specifications effort.
4. On non-ABS models, wipe the brake pipe connectors and install them in the master cylinder ports at the locations marked during removal. Tighten the union nuts to the torque specified in Specifications. Install the master cylinder and fill it with fresh fluid, then check all connections for leaks.
5. On models with ABS, install the master cylinder and fill it with fresh fluid, then check all couplings for leaks. Bleed the cylinder as described in Section Bleeding the hydraulic system of the brakes. Wipe the brake pipe connectors and install them in the master cylinder ports. Tighten the union nuts, being careful not to overtighten them - use a torque wrench and a special adapter.
6. On all models, completely bleed the brake hydraulic system as described in Section Bleeding the hydraulic system of the brakes.