Note: A failed brake master cylinder must be replaced. Manufacturers do not recommend attempting to perform a refurbishment of the brake master cylinder.
1. The master brake cylinder is located in a niche under the windshield, secured to the brake booster assembly and covered with a cover (see accompanying illustration).
12.1. Protective cover (7) of the CGT and vacuum booster assembly: 8. Engine compartment bulkhead seal
2. Remove the protective cover and, if necessary, remove the rubber seal of the engine compartment bulkhead to the required length (see illustration 12.1).
3. Remove the brake fluid reservoir cap and pump out as much of the fluid as possible (use a syringe or a rubber bulb).
4. Place rags under the fittings and prepare plugs to seal the open ends of the brake lines to prevent dirt from entering the system.
Warning: Brake fluid is an aggressive chemical compound and when in contact with body panels it destroys the paintwork. Before starting the procedure, cover the fenders and front panel of the car with special covers or just old blankets.
5. Disconnect the brake fluid level switch wiring connector from the brake master cylinder reservoir (see accompanying illustration). On models with manual transmission, disconnect the clutch hydraulic line tube from the master cylinder reservoir.
12.5. Master brake cylinder (6) with reservoir: 1. Tank lid; 2. Electrical wiring connector; 3. Clutch hydraulic supply hose (models with manual transmission); 4. Brake line guide; 5. Brake line union nuts
6. Remove the guide from the engine compartment bulkhead and loosen the union nuts securing the brake lines to the master cylinder (see illustration 12.5). To avoid rounding the nut splines, loosen them using a special open-end wrench with a slotted head. Pulling slightly outward, separate the brake lines from the master cylinder nipples.
7. Loosen the 2 mounting nuts and remove the master cylinder together with the reservoir and switch-sensor from the vacuum brake booster assembly - try not to splash the hydraulic fluid filling the cylinder on the painted body panels. If necessary, disconnect the reservoir from the master cylinder.
8. The brake master cylinder is installed in the reverse order of its removal. Do not forget to replace the removed gaskets.
9. After installation is complete, fill the cylinder and reservoir with brake fluid and bleed the system (see Section 3). Bring the fluid level up to the "MAX" mark (see Chapter 1) and tighten the tank cap securely.
10. Before operating the vehicle, make sure that the brake system is functioning properly.
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