Hyundai Coupes/Sedans 1994-1998 Repair Guide

Master Cylinder

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CAUTION
Be careful not to spill brake fluid on the painted surfaces of your car. The brake fluid will cause damage to the paint.

REMOVAL & INSTALLATION



See Figures 1 through 10



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Fig. Fig. 1: Master cylinder assembly-Elantra and Tiburon



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Fig. Fig. 2: Master cylinder assembly-Excel, Scoupe and Accent



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Fig. Fig. 3: Master cylinder assembly-Sonata



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Fig. Fig. 4: The master cylinder is attached to the power brake booster on the firewall



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Fig. Fig. 5: Disconnect the brake fluid level sensor....



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Fig. Fig. 6: .... siphon most of the brake fluid from the reservoir....



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Fig. Fig. 7: ....using a flare nut wrench, loosen the brake lines....



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Fig. Fig. 8: ....disconnect the brake lines and cap them to prevent the entry of dirt or moisture....



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Fig. Fig. 9: ....remove the master cylinder mounting bolts....



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Fig. Fig. 10: ....and lift the master cylinder assembly from the vehicle

  1. Place a drain pan under the master cylinder to catch dripping brake fluid.
  2.  
  3. Disconnect the fluid level sensor.
  4.  
  5. Remove the cap and siphon most of the brake fluid from the reservoir.
  6.  
  7. Disconnect the tubes from the master cylinder.
  8.  

On Sonata V6 with rear disc brakes, disconnect the brake lines without removing the proportioning valves.

  1. Remove the master cylinder and gasket from the booster.
  2.  

To Install:
  1. Inspect master cylinder gaskets and/or O-ring for damage and replace as necessary.
  2.  
  3. If a new or rebuilt master cylinder is being installed, the master cylinder must be bench bled prior to installation.
    1. Mount the master cylinder in a bench vice.
    2.  
    3. Fill the reservoir with fluid.
    4.  
    5. Install tubes on the master cylinder outlet ports and submerge the tubes in the reservoir fluid.
    6.  

  4.  

Master cylinder bench bleeding kits are available from aftermarket suppliers. Some new and rebuilt master cylinders contain bleeding kits as part of the package.

    1. Use a rod to slowly activate the master cylinder piston. Bubbles will appear in the reservoir fluid.
    2.  
    3. Continue activating the master cylinder piston until no bubbles are present.
    4.  


  1. Position the master cylinder on the booster and tighten mounting bolts to 10-16 ft. lbs. (14-22 Nm) on Sonata or 6-9 ft. lbs. (8-12 Nm) for all others.
  2.  
  3. Connect the brake lines to the master cylinder. Torque the tubes to 9-12 ft. lbs. (13-17 Nm).
  4.  
  5. Bleed the brake system.
  6.  

 
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