Diesel Data: Automotive Repair

Brake Master Cylinder: Service and Repair






REMOVAL
1. REMOVE BATTERY
2. DISCONNECT LEVEL WARNING SWITCH CONNECTOR
3. DRAW OUT FLUID WITH SYRINGE

NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately.





4. M/T: DISCONNECT RESERVOIR HOSE
5. DISCONNECT BRAKE LINE





a. w/o ABS: Using SST, disconnect the 5 brake lines from the master cylinder and 3-way union.
SST 09023-00100
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)
w/ ABS: Using SST, disconnect the 2 brake lines from the master cylinder.
SST 09023-00100
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)





6. REMOVE MASTER CYLINDER
a. Remove the 2 mounding nuts.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
b. w/o ABS: Pull out the check valve bracket, 3-way and master cylinder.
c. w/ ABS: Pull out the check valve bracket and master cylinder.
d. Remove the gasket from the master cylinder.





7. REMOVE RESERVOIR
a. Pull out the reservoir stopper.

HINT: At the time of installation, make sure to insert the reservoir stopper through holes of the reservoir and the master cylinder groove.

b. Remove the reservoir and 2 grommets.
c. Remove the cap and strainer from the reservoir.

INSTALLATION
Installation is in the reverse order of removal.

HINT:
^ Before installation, adjust length of brake booster push rod.
^ After installation, fill the brake reservoir with brake fluid, bleed the brake system, and check for leaks.
^ Check and adjust brake pedal.