CAUTION: It is important that the following

Assembling master cylinder 21. Fit a new retaining ring on outer surface of

CAUTION: It is important that the following

instructions are carried out precisely, 22. Fit two new reservoir seals in ir respective ports. otherwise damage could be caused to new 23. Fit a new vacuum seal to either primary plunger

seals when inserting plungers into cylinder bore. Generous amounts of new brake fluid should be

used to lubricate parts during assembly. 24. Lubricate vacuum seal with brake fluid, fit

NOTE: Thoroughly check that no debris is lodged in fluid passageways and drillings.

If debris is found, carefully remove, 25. Lubricate a new water ingress seal with brake

re-clean cylinder and re-check.

16. Fit new swirl tube to bottom of cylinder bore.
26. Roll reservoir into top of master cylinder,

27. Fit master cylinder to servo.
28. Reconnect battery, and road test vehicle.
17. Lubricate secondary plunger and cylinder bore. Offer plunger assembly to cylinder until recuperation seal is resting centrally in mouth of bore. Gently introduce plunger with a circular rocking motion, as illustrated. Ensuring that seal does not become trapped, ease seal into bore and slowly push plunger down bore in one continuous movement.
18. Fit primary plunger assembly using same method as for secondary plunger, push plunger down bore.
19. Fit original guide ring to support primary plunger.
20. Coat a new ’O’ ring with brake fluid and fit to its respective groove on outer location surface of master cylinder.

CAUTION: ’O’ ring should not be rolled down outer location surface of master cylinder but should be slightly stretched and eased down cylinder and into its groove. Do not over stretch seal.

master cylinder ensuring that serrations of ring are facing mounting flange.

or to bottom of transfer housing bore, open face of seal towards primary plunger guide ring.

transfer housing to master cylinder, push housing fully up to cylinder mounting flange. Do not adjust transfer housing after fitting.

fluid, slightly stretch seal and ease it down housing until seal is in correct position between housing and flange.

reversing procedure described in instruction 3. See Repair, Master cylinder