Removing
On models before 2001, remove the air filter cover and the fuse and relay box from the left side of the engine compartment.
Pic. 11.35. Master brake cylinder: A - electrical connector; B - places of connection of brake pipes; C - nuts
Disconnect the electrical connector from the brake fluid level sensor (pic. 11.35).
Remove the cap from the compensation tank of the brake system and, using a syringe, pump out the brake fluid.
Mark the brake pipes suitable for the main brake cylinder. Place a clean rag under the brake master cylinder to catch any leaked brake fluid.
Turn away connecting nuts of fastening of brake tubes and take away tubes aside from the main brake cylinder. Close the ends of the tubes with suitable plugs.
Warning! The brake fluid used in the hydraulic brake system is poisonous, so if it comes into contact with your skin, immediately flush the affected area with plenty of water. Brake fluid dissolves paint and plastic, so if fluid comes into contact with your vehicle's paintwork, wash it with plenty of water.
Turn out two nuts and remove the main brake cylinder from the vacuum amplifier of brakes together with a lining. Check up a condition of a sealing ring in an end face of the main brake cylinder and if necessary replace it.
Installation
Pic. 11.41. Gap between pusher (2) brake booster and piston (1) master brake cylinder: X = 0 mm
Before installing a new brake master cylinder, check the clearance between the vacuum booster tappet and the brake master cylinder piston (see fig. 11.41). If necessary, adjust the length of the pusher.
Before installing the master brake cylinder, fill it with brake fluid and remove air, for which fix the master brake cylinder in a vice and close the outlet holes of the master brake cylinder with threaded plugs.
Fill the reservoir with clean brake fluid.
Turn out one stopper and, moving the piston in the main brake cylinder, squeeze out air from it.
Before releasing the piston, screw the screw plug back into place.
Repeat the bleeding operation until only clean brake fluid comes out of the hole without air bubbles. Repeat the operation to remove air from the brake master cylinder at the second outlet.
Install the brake master cylinder with a new gasket on the brake booster studs and secure with nuts, hand-tight at this stage.
Remove the screw plugs from the brake master cylinder and install the brake pipes in their place.
Finally tighten the brake master cylinder nuts.
Pour brake fluid into the reservoir of the brake system.
Connect the electrical connector to the brake fluid level sensor.
Pic. 11.36. Removal of air from the main brake cylinder
Remove the air from the brake master cylinder that got there when installing the brake pipes. Press the brake pedal sharply, unscrew the nut securing the brake pipe to the brake master cylinder by half a turn while pressing the pedal (pic. 11.36). By continuing to press a pedal, force out the liquid which is in system together with air. After the pedal reaches the extreme forward position and the outflow of fluid stops, tighten the brake pipe mounting nut. Repeat these operations until the release of air from the master brake cylinder stops.