Master Cylinder Replacement - Honda Civic 2002-2003 Service Manual

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Master Cylinder Replacement
NOTE: 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.
1. Remove the air cleaner assembly (A).
2. Disconnect the brake fluid level
Sensor
connector
(A).
F
15N·m
D
(1.5 kgf·m, 11lbf·ftl
B
H
15N·m
(1.5 kgf·m,
11Ibf·ft)
3. Remove the clutch reservoir (8) and engine wire
harness clip (C) from the master cylinder mounting
base (D).
4. Remove the reservoir cap and brake fuid from the
reservoir.
5. Remove the reservoir (E) on the master cylinder
mounting base.
6. Disconnect the brake lines (F) from the master
cylinder (G). To prevent spills, cover the hose joints
with rags or shop towels.
7. Remove the master cylinder mounting nuts (H) and
washers.
8. Remove the master cylinder from the brake booster.
Se careful not to bend or damage the brake lines
when removing the master cylinder.
9. Remove the rod seal
(I)
from the master cylinder.
10. Install the master cylinder in the reverse order of
removal, and note these items:
• Replace all the rubber parts with new ones
whenever the master cylinder is removed.
Check the push rod clearance before installing the
master cylinder, and adjust it if necessary (see
page 19-16).
Use a new rod seal on reassembly.
Coat the inner bore lip and outer circumference
of the new rod seal (A) with the recommended
seal grease in the master cylinder set.
Install the rod seal onto the master cylinder with
its grooved side (S) toward the master cylinder.
Check the brake pedal height and free play after
installing the master cylinder, and adjust it if
necessary (see page 19-6).
MASTER
CYLINDER
SIDE
19-15