Assembly Procedure
WARNING: This page is about a different car, the 2005 Suzuki Swift +, 2005 Pontiac Wave, and 2005 Chevrolet Aveo. However, it is still accessible from the selected car via links, so may be relevant.
- Clean all parts with denatured alcohol or clean brake fluid. Dry the parts with compressed air.
- Inspect the master cylinder bore for scoring or corrosion. If scoring or corrosion is evident, replace the master cylinder body.
- Lubricate the master cylinder bore with clean brake fluid. The non-ABS master cylinder is shown.
- Carefully insert the secondary piston assembly bore until the secondary piston contacts the base of the cylinder body. Use a wood or a plastic drift, if necessary.
- Insert the primary piston.
- Press the pistons into the cylinder bore using a wooden or a plastic drift.
- Insert the new retaining ring into the groove in the cylinder bore. The non-ABS cylinder body is shown. Remove the welding rod.
- Move the pistons backward and forward after installation to check for free movement.
- Lubricate the seal ring and insert the seal on the shaft into the cylinder bore. The open side must face outward until the seal rests on the piston.
- Install the brake fluid reservoir to the master cylinder. Refer to Master Cylinder Reservoir Replacement .
- Install the master cylinder assembly. Refer to Master Cylinder Replacement .
- Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
- Bleed the braking system. Refer Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake System Bleeding (Pressure) .
- Lower the vehicle.
CAUTION:
Refer to Brake Fluid Caution
in Cautions and Notices.
NOTE:
Do not use abrasives in the master cylinder bore. Abrasives can damage the bore.
IMPORTANT:
Rubber parts and retaining rings must be discarded and replaced with new parts.
IMPORTANT:
When installing the new retaining ring, take care not to damage the cylinder bore.