Removal
1. The master brake cylinder is installed in the engine compartment on the brake booster housing.
2. Remove the brake fluid from the reservoir using a syringe.
3. Prepare rags and plugs for the brake fluid reservoir pipes.
Caution: Brake fluid may damage painted surfaces of your vehicle.
4. Loosen the nuts securing the brake pipes to the master cylinder. Use a special wrench to prevent damage to the brake pipe nuts.
5. Carefully remove the brake pipes and plug the hole.
6. Disconnect the electrical connector, unscrew the nuts securing the cylinder to the brake booster. Remove the cylinder from the studs and remove it from the car.
Repair
7. Before starting repairs, purchase a repair kit for this model of the master brake cylinder.
8. Loosen the brake fluid reservoir clamp and remove the reservoir from the cylinder.
Fig. 7.8 Assembly of a typical brake master cylinder unit
9. Remove the outer snap ring, washer, cover and bushing.
Fig. 7.9 Master cylinder disassembly procedure
10. Secure the brake cylinder in a vice and use a punch or screwdriver to push the secondary piston all the way into the opposite end of the master cylinder. While holding the piston in this position, remove the lock bolt on the side of the cylinder.
Fig. 7.10 Press the secondary piston and remove the lock bolt and inner lock ring
11. While holding the piston down, carefully remove the inner retaining ring.
12. Now you can remove all the internal parts of the brake cylinder. Remember the relative positions of the components.
Fig. 7.12 Disassembling the master cylinder
Attention: the two springs have different characteristics, do not confuse them!
13. Carefully inspect the inside surface of the master cylinder. Any deep scratches or other damage require replacement of the entire cylinder.
14. Replace all parts included in the repair kit. Wash the remaining parts in clean brake fluid. Lubricate the brake fluid in time, and tighten the connections.
15. Lower the assembled parts into the cylinder bore, press them to the lower end, install the lock bolt with a new copper washer.
16. Install the new inner snap ring, making sure it is seated in the groove.
17. Lubricate the seal, secondary piston seals and bushing with brake fluid. Install them together with the washers (see fig. 7.9). Install the locking ring.
18. Install the tank and securely fasten the clamp.
19. Before installing the master cylinder, it is recommended to bleed it on the workbench. This is necessary to supply pressure to the master cylinder pistons. Bleed the master brake cylinder, securing it in a vice by the mounting flange.
20. Place the threaded plugs in the inlet holes of the master cylinder so that there is no air leakage and at the same time they can be easily unscrewed.
21. Fill the reservoir with brake fluid recommended for your vehicle (see Chapter 1).
22. Unscrew one plug and press the piston to remove air from the master cylinder.
23. Screw in the plug and release the piston.
24. Repeat these operations until only brake fluid comes out of the hole. Then bleed the second circuit in the same way. Periodically top up the brake fluid in the reservoir to compensate for leaks.
25. If you don't have any suitable plugs, you can use your own finger. It's less convenient, but the result will be the same.
Installation
26. Install the brake cylinder onto the brake booster studs and tighten the mounting nuts by hand.
27. Tighten the brake pipes. Since the brake cylinder is not yet secured, this allows the pipe nuts to be threaded correctly.
28. Fully tighten the cylinder and brake pipe mounting nuts.
29. Fill the reservoir with brake fluid and bleed the brake system (see Section 10).
(Original article on the website: «hondabook.ru»)