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Master Cylinder: Installation: RHD

WARNING: This page is about a different car, the 2006 Chrysler PT Cruiser. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: The master cylinder must be bled before installing it on the vehicle.
  1. Bench bleed the master cylinder. (Refer to BRAKES/HYDRAULIC/MECHANICAL/MASTER CYLINDER - STANDARD PROCEDURE) 
  2. Wipe the face of the power brake booster clean where the master cylinder seal comes in contact when it's installed. Do not get any cleaner or debris inside the booster.
    Fig 1: Vacuum Seal On Rear Of Master Cylinder
    GC0022758Courtesy of DAIMLERCHRYSLER CORP.
    1 - MASTER CYLINDER MOUNTING FLANGE
    2 - VACUUM SEAL
    CAUTION: When installing a master cylinder on the vehicle, a NEW vacuum seal (2) MUST be installed on the master cylinder mounting flange (1).
  3. If the master cylinder does not have a NEW vacuum seal (2) installed on the mounting flange (1), remove it. Install a NEW vacuum seal on the master cylinder mounting flange making sure the seal fits squarely in its groove.
    CAUTION: If resistance is met during master cylinder insertion into power brake booster, the master cylinder push rod may not be lined up with the booster push rod. Remove the master cylinder, realign and insert it again.
  4. Line the master cylinder mounting holes up with the mounting studs on the power brake booster. Ensure the master cylinder piston push rod lines up with the booster push rod, then carefully slide the master cylinder into the power brake booster until it contacts the face of the booster.
    Fig 2: Master Cylinder Mounting Nuts
    GC0022755Courtesy of DAIMLERCHRYSLER CORP.
    1 - MASTER CYLINDER
    2 - POWER BRAKE BOOSTER
    3 - MOUNTING NUTS
  5. Install the two master cylinder mounting nuts (3). Tighten each nut to 25 N.m (221 in. lbs.).
    Fig 3: Cut And Remove End Of Port - Manual Transaxle Only
    GC0022756Courtesy of DAIMLERCHRYSLER CORP.
    1 - CUT AT CENTER OF "V" GROOVE
    2 - PORT PLUG
    3 - HYDRAULIC CLUTCH PORT
  6. If equipped with a manual transaxle and a new reservoir is being installed, using an appropriate cutting tool, cut the clutch actuator port (3) at center of the "V" groove (1) opening the port. Discard the severed plug (2).
    Fig 4: Clutch Actuator Hose To Reservoir Port Installation
    GC0022757Courtesy of DAIMLERCHRYSLER CORP.
    1 - CLUTCH ACTUATOR HOSE
    2 - HOSE CLAMP
    3 - UPSET BEAD ON PORT
  7. If equipped with a manual transaxle, slide the clutch actuator hose (1) onto the reservoir port. Install the hose clamp (2) just past the upset bead (3) on the port.
    Fig 5: RHD Primary & Secondary Brake Tubes To ICU
    GC0022761Courtesy of DAIMLERCHRYSLER CORP.
    1 - MASTER CYLINDER
    2 - SECONDARY BRAKE TUBE
    3 - PRIMARY BRAKE TUBE
    4 - HCU
    5 - LEFT FRONT CHASSIS BRAKE TUBE
  8. Connect the primary (3) and secondary (2) brake tubes to the master cylinder (1). Tighten all tube nuts to 17 N.m (145 in. lbs.).
  9. Connect the brake fluid level switch wiring connector.
  10. Install the brake booster vacuum supply hose.
  11. Fill the master cylinder to the proper level. (Refer to BRAKES/HYDRAULIC/MECHANICAL/FLUID - STANDARD PROCEDURE) 
    WARNING: Be certain a firm brake pedal is achieved prior to attempting to operate the vehicle. If a firm brake pedal cannot be achieved, bleed the brake hydraulic system and check for leaks. (Refer to BRAKES - STANDARD PROCEDURE) 
  12. Road test the vehicle to ensure proper operation of the brakes.
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