Master Cylinder Replacement (Non-ABS)

Master Cylinder Replacement (Non-ABS)

Removal Procedure

1. Loosen the air filter hose clamp and remove the air filter hose from the throttle body.
2. Unhook the air filter housing hooks and remove the top portion of the housing with the hose.




Caution: Refer to Brake Fluid Irritant Caution.

Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice.

3. Remove the master cylinder reservoir.
4. Remove the 2 brake pipes (2, 3) from the master cylinder.
5. Remove the 3 brake pipes (2, 8, 9) from the 3-way fitting (7).
6. Remove the following components from the vacuum booster:
1. The 2 nuts (10)
2. The check valve bracket (1)
3. The 3-way fitting
4. The master cylinder

Installation Procedure

1. Adjust the booster piston rod.

Caution: Refer to Brake Fluid Caution.

Notice: Refer to Filling the Master Cylinder Notice.

2. Bench bleed the master cylinder.




Notice: Refer to Fastener Notice.

3. Install the following components to the vacuum booster:
1. The master cylinder
2. The 3-way fitting (7)
3. The check valve bracket (1)
4. The 2 nuts (10)

Tighten the 2 nuts to 12.5 N.m (110.6 lb in).

4. Install the 3 brake pipes (2, 8, 9) to the 3-way fitting.

Tighten the flare nuts to 15.2 N.m (11.2 lb ft).

5. Install the 2 brake pipes (2, 3) to the master cylinder.

Tighten the flare nuts to 15.2 N.m (11.2 lb ft).

6. Install the brake fluid reservoir.
7. Install the top portion of the air filter housing. Install the hooks to the bottom portion of the housing.
8. Install the air filter hose to the throttle body. Secure the hose with the hose clamp.
9. Bleed the hydraulic brake system.
10. Inspect the brake system for leaks.
11. Measure the brake pedal travel. Adjust as necessary.