Master Cylinder Overhaul 1.6L Non-ABS

Caution: Wear safety glasses in order to avoid eye damage.

Caution: Refer to Brake Fluid Irritant Caution in the Preface section.

Caution: Refer to Brake Fluid Caution in the Preface section.

Notice: Refer to Filling the Master Cylinder Notice in the Preface section.

Notice: Refer to Honing the Master Cylinder Notice in the Preface section.

Notice: Refer to Master Cylinder Body Notice in the Preface section.

1. Remove the reservoir (3) from the master cylinder (5). Refer to Master Cylinder Reservoir Replacement .
2. Remove the master cylinder from the booster. Refer to Master Cylinder Replacement .



3. Remove the snap ring (1) from the master cylinder (2).
4. Remove the plate.
5. Remove the piston guide with the O-rings.
6. Remove the piston stopper.
7. Pull the primary piston assembly carefully from the master cylinder in order to prevent damage to the inside of the cylinder wall.
8. Remove the primary piston cup.
9. Remove the piston stopper bolt and the washer from the master cylinder.

Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury.

Notice: Do not use lubricated compressed air on brake parts as damage to rubber components may result.




10. Remove the secondary piston assembly by blowing compressed air into the stopper bolt hole (2).
11. Remove the piston cup and the secondary piston pressure cup.
12. Remove the spring.
13. Remove the O-ring.
14. Inspect the components for wear or damage. Replace the components if necessary.

Important: DO NOT reuse piston cups.

15. Wash disassembled parts with brake fluid.
16. Inspect the master cylinder bore for scoring or corrosion. Replace a damaged master cylinder.

Important: DO NOT use a cloth in order to dry the cylinder, because lint from a cloth will stick to the cylinder bore surfaces.

17. Rinse the cylinder in clean brake fluid. Shake excess rinsing fluid from the cylinder.

1. Install the O-ring to the master cylinder (2).
2. Install the spring.
3. Install the following into the master cylinder:

•	The secondary piston assembly

•	The new piston cup

•	The new secondary piston pressure cup

4. Install the following into the master cylinder:

•	The primary piston

•	The new primary piston cup

5. Install the new piston stopper.
6. Install the piston guide and the O-rings.
7. Install the plate.



8. Depress and install the snap ring (1).

Notice: Refer to Fastener Notice in the Preface section.

9. With the pistons pushed entirely inside the cylinder, install the piston stopper bolt.

Tighten
Tighten the stopper bolt to 10 N·m (88.5 lb in).

10. Install the master cylinder to the brake booster. Refer to Master Cylinder Replacement .



11. Apply a thin coat of brake fluid around the new grommets (4), and install the new grommets to the master cylinder (5).
12. Install the reservoir. Refer to Master Cylinder Reservoir Replacement .

Master Cylinder Overhaul 2.0L Non-ABS, 2.5L Non-ABS

Caution: Wear safety glasses in order to avoid eye damage.

Caution: Refer to Brake Fluid Irritant Caution in the Preface section.

Caution: Refer to Brake Fluid Caution in the Preface section.

Notice: Refer to Filling the Master Cylinder Notice in the Preface section.

Notice: Refer to Honing the Master Cylinder Notice in the Preface section.

Notice: Refer to Master Cylinder Body Notice in the Preface section.

1. Remove the reservoir (2) from the master cylinder (4). Refer to Master Cylinder Reservoir Replacement .
2. Remove the master cylinder from the booster. Refer to Master Cylinder Replacement .



3. Remove the piston stopper snap ring (1) from the master cylinder (2).
4. Remove the piston stopper.
5. Remove the cylinder cup.
6. Remove the plate.
7. Pull the primary piston assembly and the O-ring carefully from the master cylinder in order to prevent damage to the inside of the master cylinder wall.
8. Remove the secondary piston stopper bolt and the washer from the master cylinder.

Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury.

Notice: Do not use lubricated compressed air on brake parts as damage to rubber components may result.

9. Remove the secondary piston assembly by blowing compressed air into the secondary piston stopper bolt hole.
10. Remove the piston cup and the secondary piston pressure cup.
11. Remove the spring.
12. Inspect the components for wear or damage. Replace the components if necessary.

Important: DO NOT reuse piston cups.

13. Wash disassembled parts with brake fluid.
14. Inspect the master cylinder bore for scoring or corrosion. Replace a damaged master cylinder.

Important: DO NOT use a cloth in order to dry the cylinder, because lint from a cloth will stick to the cylinder bore surfaces.

15. Rinse the cylinder in clean brake fluid. Shake excess rinsing fluid from the cylinder.

1. Install the spring to the master cylinder (2).
2. Install the following to the master cylinder:

•	The new piston cup

•	The secondary piston assembly

•	The new secondary piston pressure cup

3. Install the O-ring and the primary piston to the master cylinder.
4. Install the plate.
5. Install the new cylinder cup.
6. Install the piston stopper.



7. Depress and install the piston stopper snap ring into the master cylinder (2).

Notice: Refer to Fastener Notice in the Preface section.

8. With the pistons pushed entirely inside the cylinder, install the piston stopper bolt.

Tighten
Tighten the stopper bolt to 10 N·m (88.5 lb in).

9. Install the master cylinder to the brake booster. Refer to Master Cylinder Replacement .



10. Apply a thin coat of brake fluid around the new grommets (3), and install the grommets to the master cylinder (4).
11. Install the reservoir. Refer to Master Cylinder Reservoir Replacement .

Master Cylinder Overhaul ABS

Caution: Refer to Brake Fluid Irritant Caution in the Preface section.

Caution: Refer to Brake Fluid Caution in the Preface section.

Notice: Refer to Filling the Master Cylinder Notice in the Preface section.

Notice: Refer to Honing the Master Cylinder Notice in the Preface section.

Notice: Refer to Master Cylinder Body Notice in the Preface section.

1. Remove the reservoir (2) from the master cylinder (4). Refer to Master Cylinder Reservoir Replacement .
2. Remove the master cylinder from the booster. Refer to Master Cylinder Replacement .



3. Remove the piston stopper snap ring (1) from the master cylinder (2).
4. Remove the piston stopper.
5. Remove the cylinder cup.
6. Remove the plate.
7. Pull the primary piston assembly carefully from the master cylinder in order to prevent damage to the inside of the cylinder wall.



8. Remove the secondary piston assembly carefully from the master cylinder (1) by tapping the flange on a piece of wood (2) or two soft objects.
9. Remove the secondary piston pressure cup.
10. Remove the piston cup.
11. Remove the O-ring.
12. Inspect the components for wear or damage. Replace the components if necessary.

Important: DO NOT reuse piston cups.

13. Wash disassembled parts with brake fluid.
14. Inspect the master cylinder bore for scoring or corrosion. Replace a damaged master cylinder.

Important: Do NOT use a cloth in order to dry the cylinder, because lint from a cloth will stick to the cylinder bore surfaces.

15. Rinse the cylinder in clean brake fluid. Shake excess rinsing fluid from the cylinder.

1. Install the O-ring to the master cylinder (2).
2. Install the following to the master cylinder:

•	The new piston cup

•	The secondary piston assembly

•	The new secondary piston pressure cup

3. Install the primary piston assembly to the master cylinder.
4. Install the plate.
5. Install the cylinder cup.
6. Install the piston stopper.



7. Depress and install the piston stopper snap ring into the master cylinder (2).
8. Install the master cylinder to the brake booster. Refer to Master Cylinder Replacement .



9. Apply a thin coat of brake fluid around the new grommets (3), and install the grommets to the master cylinder (4).
10. Install the reservoir. Refer to Master Cylinder Reservoir Replacement .