Note: The nuts that hold the brake pipes are usually very tight. When trying to loosen them with a regular wrench, the edges of the nuts are crushed, so we recommend using special wrenches for brake pipes.
1. Disconnect the wire from the negative terminal of the battery.
2. Disconnect the expansion tank from its mount and move it to the side without disconnecting the hoses or draining the coolant (see Replacing the brake master cylinder reservoir).
Note: Removal of the expansion tank is necessary to gain access to the clutch master cylinder feed hose and the right brake master cylinder mounting nut.
3. Unscrew the cap of the brake master cylinder reservoir and pump out the brake fluid from the reservoir, for example, with a large medical syringe. Install the cap to prevent dirt from getting into the brake master cylinder reservoir.
4. Squeeze the clamps of the brake fluid level sensor wiring harness connector…
5. …disconnect the wiring harness connector from the sensor.
6. Pull up on the brake fluid level sensor wiring harness…
7. …disconnect the harness from the tank.
8. Disconnect the hose from the reservoir to the clutch master cylinder.
Note: Immediately after disconnecting the hose from the reservoir, plug its opening without lowering the hose down. There will be some working fluid left in the hose; after installing the reservoir and connecting the hose to it, there is no need to bleed air from the clutch release hydraulic drive.
Note.
- On a vehicle with an automatic transmission, a spring-loaded plug is installed on the nipple of the master brake cylinder reservoir instead of the hose tip.
- There is no need to remove it unless necessary.
9. Unscrew the nuts securing the two pipelines to the cylinder…
10. …and move the pipes to the side.
Note: Seal the pipes using any available method (for example, by putting protective caps on their ends to release air), to prevent brake fluid from leaking out.
11. Disconnect the wiring harness from the battery mounting shelf and move it to the side (see Removal and installation the battery mounting shelf).
Note: It is necessary to disconnect the wiring harness because it obstructs access to the right brake master cylinder mounting nut.
12. Turn away the left…
13. …and the right nut securing the master brake cylinder to the vacuum booster...
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14. …remove the nuts from the brake booster mounting bolts…
15. …and remove the master brake cylinder assembly with the reservoir.
16. If the new master cylinder does not have a reservoir or it is necessary to replace the rubber connecting bushings of the reservoir, remove the reservoir by unscrewing the screw that secures it and removing its pipes from the connecting bushings (see Replacing the brake master cylinder reservoir).
17. If during operation a leak of brake fluid was observed through the connecting bushings, remove the bushings from the holes in the cylinder body.
Attention! Reuse of connecting bushings is not allowed, replace them with new ones.
18. Remove the rubber sealing ring from the master cylinder housing.
Caution! Replace the master cylinder sealing ring with a new one each time the connection is disassembled.
19. If during operation the brake fluid level sensor fails, to replace it, turn the sensor clockwise until it stops..
20. …and remove the sensor from the tank.
21. Install the brake master cylinder and all removed parts in the reverse order of removal, fill with brake fluid and bleed air from the system (see Bleeding the hydraulic brake system).
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