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MASTER CYLINDER, Brake: Installation: Right-Hand-Drive

WARNING: This page is about a different car, the 2009 Dodge Caliber. 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. See Brakes/Hydraulic/Mechanical/MASTER CYLINDER, Brake - Standard Procedure 
  2. Wipe the face of the power brake booster clean where the vacuum seal on the rear of the master cylinder comes in contact when it's installed. Do not get any cleaner or debris inside the booster.
    Fig 1: SEAL ON REAR OF MASTER CYLINDER
    GC0083936Courtesy of CHRYSLER LLC
    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) 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. Install the master cylinder into the engine compartment as follows:
    1. Starting on the inboard side of the air conditioning lines behind the engine, guide the master cylinder below the air conditioning lines, then up in front of the power brake booster.
    2. Line up the master cylinder mounting holes 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
    GC0083933Courtesy of CHRYSLER LLC
  5. Install two NEW master cylinder mounting nuts (3). Tighten each nut to 25 N.m (18 ft. lbs.).
    Fig 3: PRIMARY AND SECONDARY BRAKE TUBES - RHD
    GC0083935Courtesy of CHRYSLER LLC
  6. Connect the primary (1) and secondary (2) brake tubes to the master cylinder outlet ports. Tighten the tube nuts to 17 N.m (150 in. lbs.).
    Fig 4: CUT AND REMOVE CLUTCH PORT PLUG
    GC0082335Courtesy of CHRYSLER LLC
  7. If equipped with a manual transaxle and a new reservoir is being installed, using an appropriate cutting tool, cut the clutch actuator port at the center of the "V" groove (2) opening the hydraulic clutch port (1). Discard the severed plug (3).
    Fig 5: CLUTCH ACTUATOR HOSE AT MASTER CYLINDER
    GC0083932Courtesy of CHRYSLER LLC
  8. If equipped with a manual transaxle, slide the clutch actuator hose (2) onto the reservoir port (1). Install the hose clamp just past the upset bead on the port.
    Fig 6: BRAKE FLUID LEVEL SWITCH CONNECTOR - RHD
    GC0083934Courtesy of CHRYSLER LLC
  9. Connect the wiring harness connector (1) to the brake fluid level switch (2).
  10. Install the engine appearance cover.
  11. Connect the negative (ground) cable on the battery.
  12. Fill the master cylinder reservoir to the proper level. See 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. See Brakes - Standard Procedure 
  13. Road test the vehicle to ensure proper operation of the brakes.
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