Subaru Coupes/Sedans/Wagons 1985-1996 Repair Guide

Master Cylinder

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REMOVAL & INSTALLATION



Justy
  1. Disconnect the negative battery cable.
  2.  
  3. Siphon the brake fluid out of the master cylinder reservoir.
  4.  
  5. Disconnect the electrical connector from the brake fluid warning light.
  6.  
  7. Disconnect and cap the brake pipes from the master cylinder.
  8.  
  9. Remove the two master cylinder mounting nuts.
  10.  
  11. Remove the master cylinder from the mounting studs.
  12.  

To install:
  1. If a new master cylinder is being installed it must be bench bled first.
  2.  
  3. Install the master cylinder on the mounting studs and tighten the mounting nuts to 10 ft. lbs. (13 Nm).
  4.  
  5. Connect the brake pipes to the master cylinder and tighten the fittings to 13 ft. lbs. (18 Nm).
  6.  
  7. Connect the electrical connector to the brake fluid warning switch.
  8.  
  9. Refill the master cylinder.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Bleed the brake system.
  14.  

Coupe, Sedan, XT, Loyale, Wagon and Brat

See Figures 1 and 2

Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the master cylinder and booster assembly-Coupe, Sedan, XT, Loyale, Wagon and Brat



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Fig. Fig. 2: Use a flare-end wrench to disconnect the brake lines from the master cylinder

  1. Disconnect the negative battery cable.
  2.  
  3. Siphon the brake fluid from the master cylinder.
  4.  
  5. Disconnect the brake fluid level indicator harness.
  6.  
  7. Disconnect and cap the brake lines from the master cylinder.
  8.  
  9. Remove the master cylinder mounting nuts and remove the master cylinder.
  10.  

To install:
  1. Before installing a new master cylinder it must first be bench bled.
  2.  
  3. Position the master cylinder on the power booster and install the master cylinder mounting nuts. Tighten the mounting nuts to 10 ft. lbs. (14 Nm).
  4.  
  5. Connect the brake lines to the master cylinder and tighten the fittings to 11 ft. lbs. (15 Nm).
  6.  
  7. Connect the brake fluid level indicator.
  8.  
  9. Refill the master cylinder and bleed the brake system.
  10.  
  11. Connect the negative battery cable.
  12.  

Impreza
  1. Disconnect the negative battery cable.
  2.  
  3. Siphon the brake fluid out of the master cylinder reservoir.
  4.  
  5. Disconnect the electrical harness from the brake fluid warning light.
  6.  
  7. Disconnect and cap the brake pipes from the master cylinder.
  8.  
  9. Remove the two master cylinder mounting nuts.
  10.  
  11. Remove the master cylinder from the mounting studs.
  12.  

To install:
  1. If a new master cylinder is being installed it must be bench bled first.
  2.  
  3. Install the master cylinder on the mounting studs and tighten the mounting nuts to 10 ft. lbs. (13 Nm).
  4.  
  5. Connect the brake pipes to the master cylinder and tighten the fittings to 13 ft. lbs. (18 Nm).
  6.  
  7. Connect the electrical harness to the brake fluid warning switch.
  8.  
  9. Refill the master cylinder.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Bleed the brake system.
  14.  

Legacy

See Figures 3, 4 and 5

Click image to see an enlarged view

Fig. Fig. 3: Siphon as much brake fluid out of the reservoir



Click image to see an enlarged view

Fig. Fig. 4: Unfasten the reservoir electrical harness



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Fig. Fig. 5: Loosen the master cylinder retainer nuts

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect and plug the brake lines at the master cylinder.
  4.  
  5. Thoroughly drain the fluid from the master cylinder before performing any removal procedures.
  6.  
  7. Disconnect the fluid level sensor electrical harness connector from the master cylinder.
  8.  
  9. Remove the master cylinder to power brake booster retaining nuts. Remove the master cylinder from its mounting.
  10.  

To install:
  1. Bench bleed the master cylinder prior to installation.
  2.  
  3. Install the master cylinder on the power booster and tighten the nuts to 7-13 ft. lbs. (10-18 Nm).
  4.  
  5. Connect the fluid level indicator.
  6.  
  7. Connect the brake lines and tighten the flarenut to 9-13 ft. lbs. (13-18 Nm).
  8.  
  9. Bleed the brake system as required.
  10.  

SVX
  1. Siphon the brake fluid out of the master cylinder reservoir.
  2.  
  3. Disconnect the electrical harness from the brake fluid sensor.
  4.  
  5. Cap and disconnect the brake lines from the master cylinder.
  6.  
  7. Remove the master cylinder mounting nuts.
  8.  
  9. Remove the master cylinder.
  10.  

To install:
  1. If installing a new master cylinder, bench bleed prior to installation.
  2.  
  3. Install the master cylinder on the booster studs.
  4.  
  5. Install the master cylinder mounting nuts and tighten to 10 ft. lbs. (14 Nm).
  6.  
  7. Connect the brake lines to the master cylinder and tighten the fittings to 11 ft. lbs. (15 Nm).
  8.  
  9. Connect the electrical connector to the brake fluid sensor.
  10.  
  11. Refill the master cylinder with fluid.
  12.  
  13. Bleed the brake system.
  14.  

 
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