Note: A failed GTZ must be replaced. Manufacturers do not recommend attempting to rebuild the brake master cylinder.
1. The brake master cylinder is located in the engine compartment of the vehicle and is attached to the brake booster assembly.
2. Remove the expansion tank from the holders and put it aside. Remove the brake fluid reservoir cap and pump out as much fluid as possible (use a syringe or rubber bulb).
3. Place a rag under the fittings and prepare plugs or plastic bags to plug the open ends of the brake lines to prevent dirt from entering the system.
Attention: Brake fluid is one of the aggressive chemical compounds and, in contact with body panels, destroys the paintwork. Before proceeding with the procedure, cover the wings and front panel of the car with special covers, or just old blankets.
4. Disconnect the connector and disconnect the electrical wiring of the brake fluid level sensor-switch from the GTZ tank (see resist. illustration).
10.4 Brake master cylinder (5) with tank (2) - the arrows indicate the fixing nuts: 1. Expansion tank; 3. Tank cover; 4. Wiring connector; 6. Brake lines
5. Loosen the nuts of the fitting units for connecting to the GTZ of the brake lines (see illustration 10.4). To avoid rounding of the splines of the nuts, use a special box wrench with a split head to loosen them. Slightly pulling outward, separate the brake lines from the master cylinder fittings.
6. On models with a manual transmission, disconnect the hydraulic clutch pipe from the GTZ reservoir.
7. Loosen 2 fixing nuts (see illustration 10.4) and remove the master cylinder along with the reservoir and sensor-switch from the vacuum brake booster assembly - try not to spill the hydraulic fluid filling the cylinder onto the painted body panels. Remove the seal.
8. The GTZ is installed in the reverse order of its removal. Do not forget to replace the removed gaskets.
9. After installation, fill the cylinder and reservoir with brake fluid and bleed the system (see Section 3). Bring the fluid level up to the mark «MAX» (see chapter 1) and tighten the reservoir cap tightly.
10. Before starting the operation of the car, make sure that the brakes are working properly.
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