Note. Read the warning about the danger of brake fluid given at the beginning of the operation before starting work paragraph 2.
Removing
1. On left-hand drive models, remove the battery and battery tray. as described in chapter 5A. Depending on the model and operating space, remove the air filter and the remaining air intake piping as described in the appropriate part to facilitate access to the master cylinder chapter 4.
2. Unscrew the cap on the filler neck of the reservoir of the hydraulic drive of the brakes and use a suitable syringe or pipette to pump out the brake fluid from the reservoir.
Note. Do not suck out brake fluid by mouth as it is poisonous.
3. Disconnect the electrical connector of the liquid level sensor on the tank wall and release the electrical wiring from the appropriate clamp.
4. Place an absorbent rag under the master cylinder to collect the leaking fluid and be prepared for the brake fluid to leak out.
5. Clean the area around the brake line fittings on the side of the master cylinder. Mark the location of the connections, unscrew the union nuts/screws and carefully move the pipelines. If fittings are used «banjo» (hollow bolt), remove the copper washers located on each side of the connection and purchase new washers to install. Properly plug the pipe ends and master cylinder ports to minimize brake fluid leakage and prevent dirt from entering the system.
6. Turn away two nuts of fastening of the main cylinder to the vacuum amplifier of brakes and then remove the main cylinder from the vacuum amplifier. If the o-ring installed at the rear of the master cylinder shows signs of damage or deterioration, it should be replaced.
7. If necessary, you can remove the hydraulic reservoir from the master cylinder. To fix the tank in a regular place, various methods are used depending on the type of master cylinder. It can be a combination of a nut, bolt and retaining clip located under the master cylinder, a roll pin, or a retainer and clip. Remove the appropriate fastener, then pull the reservoir up and out of the two sealing grommets in the master cylinder.
Repair
8. Before making a decision to repair the master cylinder, make sure that the necessary spare parts are available. While Peugeot/Citroen dealers supply interior parts for some (but not all) used master cylinders, there is a possibility. that a repair kit can be purchased from auto parts stores. Purchase the correct repair kit for the master cylinder you are working on. Mark the location of all parts to ensure proper installation, and lubricate the new seals with clean brake fluid. Follow the assembly instructions included with the repair kit.
Installation
9. Carefully install the brake fluid reservoir in its original place (if it was taken), making sure that it is installed correctly in the rubber bushings. Install the appropriate fasteners to secure the reservoir to the master cylinder.
10. Install the master cylinder to the brake booster, making sure the booster pusher is centered in the master cylinder bore. Install the master cylinder nuts and tighten them to the specified torque.
11. Wipe clean the brake line fittings, connect them to the master cylinder ports and tighten securely. If fittings are used «banjo» (hollow bolt), install new copper washers on each side of the joint.
12. Dock an electric socket of the sensor of level of a brake liquid and fix electroconducting a collar.
13. On left-hand drive models, install the battery tray and battery (see if necessary. chapter 5A). Install the air filter and air intake piping removed for access as described in the appropriate part chapter 4.
14. Fill the reservoir of the hydraulic brake drive with fresh fluid and remove air from the entire hydraulic drive, as described in paragraph 2.