Hyundai Elantra HD: Master Cylinder. Repair procedures - Brake System - Brake System - Hyundai Elantra HD 2006–2010 Service ManualHyundai Elantra HD: Master Cylinder. Repair procedures

Removal

1.
Remove air cleaner assembly (A). (Refer to EM Gr.)
2.
Disconnect the brake fluid level switch connector (A), and remove the reservoir cap (B).
3.
Remove the brake fluid from the master cylinder reservoir with a syringe.
Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.
4.
Disconnect the brake lines (A) from the master cylinder. To prevent spills, cover the hose joints with rags or shop towels.
5.
Remove the master cylinder mounting nuts (A) and washers.
6.
Remove the master cylinder (B) from the brake booster. Be careful not to bend or damage the brake lines when removing the master cylinder.

Installation

1.
Install the master cylinder (B) to the brake booster.
2.
Install the master cylinder mounting nuts (A) and washers.
Tightening torque :
9.8~15.7N.m (1.0~1.6kgf.m, 7.2~11.6lb-ft)

3.
Connect the brake lines (A) to the master cylinder.
Tightening torque :
12.7~16.7N.m (1.3~1.7kgf.m, 9.4~12.3lb-ft)

4.
Connect the brake fluid level switch connector (A).
5.
Refill the master cylinder reservoir to the MAX line.
6.
Bleed the (Refer to "Bleeding of brake system")

Disassembly

1.
Remove the reservoir cap and drain the brake fluid into a suitable container.
2.
Remove the reservoir (C) from the master cylinder(B) after remove the mounting screw (A).
3.
Remove the proportioning valves. (Conventional brake system)
4.
Remove the retainer ring (A) by using the snap ring pliers.
5.
Remove the primary piston assembly (B).
6.
Remove the pin (D) with the secondary piston (C) pushed completely using a screwdriver. Remove the secondary piston assembly (C).

Do not disassemble the primary and secondary piston assembly.

Inspection

1.
Check the master cylinder bore for rust or scratch.
2.
Check the master cylinder for wear or damage. If necessary, clean or replace the cylinder.
1.
If the cylinder bore is damaged, replace the master cylinder assembly.
2.
Wash the contaminated parts in alcohol.

Reassembly

1.
Apply genuine brake fluid to the rubber parts of the cylinder kit and grommets.
2.
Carefully insert the springs and pistons in the proper direction.
3.
Press the secondary piston (C) with a screwdriver and install the cylinder pin (D).
4.
Install the primary piston assembly (B) and the retainer ring (A).
5.
Install the proportioning valves. (Conventional brake system)
6.
Mount two grommets (D).
7.
Install the reservoir (C) to the master cylinder (B) and tighten the screw (A).

Master Cylinder. Components and Components Location
Components 1. Reservoir cap 2. Reservoir 3. Grommet 4. Cylinder pin 5. Retainer 6. Primary piston assembly 7. Secondary piston assembly 8. Master cy ...

Proportioning Valve. Description and Operation
Description Do not disassemble the proportioning valve. The proportioning valve makes the ideal distribution of fluid pressure to the front and rear brakes to prevent the brakes from skiddin ...