2020-03-02

Master Cylinder and Reservoir Assembly (Remove and Replace)

Correction Code 33170602

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Note
This procedure applies to vehicles with the vacuum brake booster only. If the vehicle has the electromechanical brake booster assembly, the master cylinder and reservoir assembly are part of the brake booster assembly. Refer to procedure 33201002 (refer to procedure).
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CAUTION
Use caution when handling the master cylinder assembly. Do not touch the outer edge of the primary piston.

Removal

  1. Disconnect 12V power (refer to procedure).
  2. Remove the wiper motor assembly (refer to procedure).
  3. Remove the underhood storage unit (refer to procedure).
  4. Disconnect the coolant level sensor connector.
  5. Release the nut that secures the coolant reservoir upper bracket (torque 5 Nm).
  6. Release the bolts (x2) that secure the coolant reservoir to the crossmember (torque 5 Nm).
  7. Carefully move the coolant reservoir out of the working area.
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    Note
    Do not spill any coolant. Ensure that the reservoir cap is installed and that no hoses are disconnected.
  8. Remove the windshield washer reservoir (refer to procedure).
  9. Using a syringe, remove all fluid from the reservoir.
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    Warning
    Do not use a syringe that has been used for oils or other petroleum products. Even trace amounts of petroleum-based fluids can damage seals throughout the brake system, leading to brake failure.
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    CAUTION
    If brake fluid is spilled on a painted surface, wash off immediately with clean water.
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    Note
    Place suitable absorbent material around the affected area to absorb any possible fluid spillage.
  10. Disconnect the brake fluid level sensor connector.
  11. Disconnect the brake booster vacuum sensor connector.
  12. Release the brake pipe unions (x2) (torque 18 Nm).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Plug pipe connections to prevent ingress of moisture or dirt.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    If brake fluid is spilled on a painted surface, wash off immediately with clean water.
    Informational PurposesAn informational icon, calling your attention
    Note
    Place suitable absorbent material around the affected area to absorb any possible fluid spillage.
  13. Remove the nuts and washers (x2) that secure the master cylinder to the brake booster (torque 25 Nm).
  14. Release the master cylinder and reservoir assembly from the brake booster.
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    CAUTION
    Ensure that the O-ring is not removed from the mating surface of the master cylinder during removal.
  15. Remove the master cylinder and reservoir assembly from the vehicle.

Installation

Installation procedure is the reverse of removal, except for the following:
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Warning
Only use cleaning agents and solvents in a well-ventilated area.
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CAUTION
Ensure that the O-ring is properly installed on the mating surface of the master cylinder before installation.
  1. Bleed the brakes (refer to procedure).