Master Cylinder Removal and Installation: Installation

Reference: MASTER CYLINDER INSPECTION 

1. Install new O-ring (2) to master cylinder assembly (1).
2. Apply grease to piston rod "A".

   Use specified grease in spare to master cylinder or brake booster as supply parts.

3. Install master cylinder assembly (1) to brake booster (3) and tighten master cylinder fixing nuts to specified torque.

   Tightening torque 

   Master cylinder fixing nut a: 18 N.m (1.8 kg-m, 13.0 lb-ft) 

   Fig 1: Identifying Master Cylinder Assembly And Brake Booster

   Courtesy of SUZUKI OF AMERICA CORP.
4. Connect brake pipe to master cylinder and tighten flare nuts to specified torque.

   Tightening torque 

   Brake pipe flare nut for M10 a: 16 N.m (1.6 kg-m, 11.5 lb-ft) 

   Brake pipe flare nut for M12 a: 19 N.m (1.9 kg-m, 14.0 lb-ft) 

   Fig 2: Connecting Brake Pipe To Master Cylinder

   Courtesy of SUZUKI OF AMERICA CORP.
5. Connect clutch reservoir hose to reservoir and install reservoir hose clamp (M/T model).
6. Connect fluid level switch connector and clamp.
7. Fill reservoir with specified brake fluid up to its MAX level.
8. After completing the work, bleed air from brake and clutch system referring to AIR BLEEDING OF BRAKE SYSTEM  and bleed air from clutch system referring to AIR BLEEDING OF CLUTCH SYSTEM (M/T model).
9. Check each installed parts for fluid leakage.
10. Check brake pedal for play referring to BRAKE PEDAL PLAY INSPECTION .
11. Perform brake test and check fluid leakage.