Spark

Master Cylinder Replacement — Right Hand Drive

Warning: Refer to Brake Fluid Irritant Warning in the Preface section.

Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution in the Preface section.

1. Place the ignition switch in the OFF position.
2. Remove the radiator surge tank to gain easy tool access. Refer to Radiator Surge Tank Replacement .
3. Apply and release the brake pedal several times until the pedal becomes firm to deplete the power vacuum brake booster vacuum reserve.
4. Thoroughly clean the master cylinder reservoir and the master cylinder body to remove any dirt and debris.
5. Disconnect the brake fluid level indicator switch electrical connector.



6. Syphon the brake fluid out of the master cylinder reservoir (1) using an air vacuum pump or a hand vacuum pump (2).



7. Disconnect the master cylinder secondary brake pipe fitting (1).

Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination.




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

Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination.




9. Remove the master cylinder nuts (1).



10. Remove the master cylinder (1) from the power vacuum brake booster.
11. Remove the brake fluid level indicator switch, if necessary. Refer to Brake Fluid Level Indicator Switch Replacement .
12. Remove the master cylinder reservoir, if necessary. Refer to Master Cylinder Reservoir Replacement .

1. Install the master cylinder reservoir, if removed. Refer to Master Cylinder Reservoir Replacement .
2. Bench bleed the master cylinder. Refer to Master Cylinder Bench Bleeding .
3. Install the brake fluid level indicator switch, if removed. Refer to Brake Fluid Level Indicator Switch Replacement .



4. Install the master cylinder (1) to the power vacuum brake booster.

Caution: Refer to Fastener Caution in the Preface section.




5. Install the master cylinder nuts (1) and tighten the nuts to 13 N·m (115 lb in).



6. Connect the master cylinder primary brake pipe fitting (1) and tighten to 18 N·m (13 lb in).



7. Connect the master cylinder secondary brake pipe fitting (1) and tighten to 18 N·m (13 lb in).
8. Connect the brake fluid level indicator switch electrical connector.
9. Install the radiator surge tank. Refer to Radiator Surge Tank Replacement .
10. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding : Pressure → Manual .