- disconnect the negative battery cable;
- disconnect the brake fluid level sensor connector in the expansion tank;
- using a large syringe or rubber bulb, remove as much brake fluid as possible from the expansion tank;
- remove the injection system ECU in the engine compartment;
- disconnect the power steering reservoir fasteners and move the reservoir toward the engine;
- remove the expansion tank from the master brake cylinder by pulling it upwards, taking measures to collect any leaking fluid;
- clean the place where the pipes connect to the main brake cylinder from dirt. Remember or mark the location of the pipes. Unscrew the connecting nipples and disconnect the pipes from the cylinder;
- take measures to prevent dirt from getting into the openings of the brake system;
- unscrew the two nuts securing the vacuum tube;
- unscrew the two nuts securing the master brake cylinder to the vacuum booster;
- remove the master brake cylinder.
Fig. 7.19. Master brake cylinder supplied as spare parts: 1 – main brake cylinder; 2, 4 – plugs; 3 – sealing ring; 5 – fastening nut
Attention! A repair kit of parts for the main brake cylinder is not produced, therefore, if the cylinder is damaged, it is replaced with a new one with mandatory replacement of the sealing ring (Fig. 7.19).
Installation procedure:
Fig. 7.20. Adjusting the pusher length: X=22.3 mm; the arrow shows the adjusting bolt of the pushrod
- before installation, check the distance X (Fig. 7.20). It should be 22.3 mm. If necessary, adjust the size using the bolt;
- clean the mating surfaces of the units to be connected;
- install a new sealing ring onto the rear end of the master cylinder;
- install the cylinder on the studs so that the pusher enters the cylinder cavity to the required depth;
- screw the mounting nuts onto the studs and tighten them to the specified torque;
- connect the pipelines to the cylinder body according to the marks made;
- lubricate the rubber seals with brake fluid, then press the expansion tank fittings into them;
- perform the remaining operations in the reverse order of removal;
- add brake fluid to the reservoir and remove air from the brake system drive.