Removal
Before removing the master cylinder, press the brake pedal several times to relieve the vacuum in the brake booster.
When removing the master cylinder, it is necessary to take into account the differences in the design of the brake system models. Description regarding brake mechanisms with ABS is given separately.
The following illustrations show the appearance of the brake master cylinder for both versions (without ABS).
View of the main brake cylinder of a car produced before mid-1995: 1 - brake lines; 2 - fastening nuts; 3 - tank; 4-pin switch
View of the main brake cylinder of a car produced since mid-1995: 1 - plug connection; 2 - brake lines; 3 - tee; 4 - master brake cylinder
1. Disconnect the ground cable from the battery.
2. Disconnect the plug connection (4) of the brake fluid emergency level sensor at the location shown in the illustration.
3. Suck the fluid out of the reservoir on the master cylinder. For this you can use a pear. To do this, you can also open the air bleed nipple from the system and drain the liquid.
4. Place a container under the tank and disconnect the pipeline (1) from the cylinder. Remember where it is connected.
5. Loosen the two mounting nuts and remove the master cylinder from the vacuum booster. Be careful not to let brake fluid come into contact with paintwork.
6. For a new model cylinder, disconnect the tee holder.
7. Remove the seals and spacer element from the same cylinder.
8. If the cylinder is being replaced, the reservoir must be removed. It sits on two rubber grommets and can be carefully pryed out with a screwdriver as shown.
Installation
The master cylinder is installed in the reverse order of removal.
1. Tighten the cylinder mounting nuts to a torque of 13 Nm, and the pipeline connection to a torque of 12 Nm. The pipeline connection at the tee is tightened to a torque of 16 Nm.
2. Finally, bleed the brake system as described in section 6.
3. If the reservoir was removed, install it on the master cylinder through the rubber bushings, lubricating them with brake fluid.
Repair of the main brake cylinder
As already mentioned, the master cylinder of a car produced since mid-1995 cannot be repaired.
Earlier cylinders can be disassembled, repaired and reassembled, but it is recommended that this be done in a workshop.
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