Brake fluid is extremely dangerous to painted, plastic or rubber surfaces. If spilled, rinse immediately with clean water. Keep brake lines and hoses clogged during disassembly. Dirt and moisture MUST NOT be allowed to enter the system. Perform work in a clean, well-lit area.
1. Use a syringe or similar tool to remove as much fluid as possible from the replenishment tank.
2. Label each brake line according to its location on the master cylinder. Use open-end wrenches to loosen and disconnect the brake lines from the master cylinder. Catch any fluid that leaks.
3. Unscrew the nuts securing the cylinder to the brake booster. Remove the master cylinder.
To install:
4. If the master cylinder has been disassembled or replaced, the tappet clearance MUST be CHECKED and adjusted prior to installation. See separate procedure.
5. Install the master cylinder onto the brake booster. Tighten the nuts to 15 Nm.
6. Connect the brake lines. Hand-tighten the fittings to avoid damaging the threads; do not handle the pipes in such a way that they are bent or twisted. Tighten the nuts to 15 Nm.
7. Fill the reservoir with clean, fresh brake fluid. Do not reuse old fluid.
8. Bleed the brake system completely.