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. Remove the intake manifold cover, if necessary. Refer to Intake Manifold Cover Replacement Intake Manifold Cover Replacement for the 2.0L or Intake Manifold Cover Replacement Intake Manifold Cover Replacement for the 2.4L engine.

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

5. 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.

6. If equipped with the manual transmission, disconnect the clutch master cylinder reservoir hose. Refer to Clutch Master Cylinder Reservoir Hose Replacement Clutch Master Cylinder Reservoir Hose Replacement.

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





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

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

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

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





12. Remove the master cylinder nuts (1).





13. Remove the master cylinder (1).

14. 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. Connect the master cylinder primary brake pipe fitting (1) and tighten to 18 Nm (13 lb ft).

5. Connect the master cylinder secondary brake pipe fitting (2) and tighten to 18 Nm (13 lb ft).

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

7. If equipped with the manual transmission, connect the clutch master cylinder reservoir hose. Refer to Clutch Master Cylinder Reservoir Hose Replacement Clutch Master Cylinder Reservoir Hose Replacement.

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

9. 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).

10. Install the intake manifold cover, if removed. Refer to Intake Manifold Cover Replacement Intake Manifold Cover Replacement for the 2.0L or Intake Manifold Cover Replacement Intake Manifold Cover Replacement for the 2.4L engine.