Master cylinder

Anticipate brake fluid flow to prevent damage to mechanical parts and bodywork around the brake system.

REMOVAL

• Position the vehicle on a two-post lift.
• Disconnect the battery, starting with the negative terminal.
• Remove the engine covers.
• Remove:

• battery,
• the battery tray,
• the injection ECU.

K4J

• Remove the air resonator.

F9Q

• Remove the turbocharger control solenoid valve (1).
• Disconnect the mass air flow sensor connector.

K4J or K4M or K9K

• Remove:

• the front left wheel,
• the splash guard.

• Remove the two air resonators (2).

• Remove:

• the air intake duct (3),
• the air duct (4),
• the air duct after the air box,
• the air box (5).

• Disconnect the electrical connector (6) on the master cylinder reservoir.
• Drain the master cylinder reservoir using a syringe.
• Remove:

• the clutch slave cylinder pipe (7),
• the brake pipes (8) on the master cylinder,
• the master cylinder mounting nuts (9) on the brake booster,
• the master cylinder assembly and the master cylinder reservoir,
• the master cylinder reservoir mounting bolt (10) on the master cylinder,
• the master cylinder reservoir.

INSTALLATION

CAUTION Always replace the master cylinder seals.

• Clip the master cylinder reservoir securely onto the master cylinder.
• Refit the master cylinder reservoir mounting bolt to the master cylinder.
• Tighten the master cylinder reservoir mounting bolt to torque (0.85 daN.m).

• Position the master cylinder in line with the brake booster so that the pushrod enters the master cylinder bore.

When refitting the master cylinder, make sure the cup is centred in the brake booster.

• Refit the master cylinder mounting nuts to the brake booster.
• Tighten the master cylinder mounting nuts to torque (5 daN.m) on the brake booster.
• Refit in the reverse order of removal.
• Tighten the brake pipe nuts to torque (1.7 daN.m) on the master cylinder.

Connect the battery; carry out the necessary relearn procedures (see Battery chapter).

• Torque the battery cover screws (0.4 daN.m).
• Bleed the brake circuit (General chapter, Bleeding the brake circuit, page 30A-5).