Page 149 of 205

)8 Chapter 9 Braking system 
8 
Fig. 9 .6 Rear wheel cylinder component s on "",I y models (Sec 8) 
I Cft,} 2 Rubber hoot 3 Pis/oil 
5 Relmll SfJflflY 6 Blcell screw 9 Scff ",',uSilll!! wtdll.:/ 10 At/jlls/my boof 
4 Seal I Retaming JlI,~tcs II Ullfufb,;,Ac oj/cUlling level 8 Wheel cyhirdcr body 
11 Dip the piSlOn(s) and plSlOn SC
12 Rein the wheel cyhnder  using il f(lversal of Ihe fcmOy.1. procedure. Note lhal on (l,lIly models t he sel l.,ldrusI1I19 .atchet is handed -RH thread  on the RH side. and Lit thread on thc LH SIde. 13 On cOlllpletion bleed the  hydraulic syslCHll ;'IS described  in Section 15. 
9 ROilr backl}lato -rClllovn! (IIHI mfittillg 
Remove th ... wheel cylllllier ~s 
Thoroughly  cle,ln the b~ckpl.1te ~nd Jxll) casing  Ihen relit the h .. 1ckplJte with reference to ChJpter 8 Jnd Section 8 01 this CIl.1pler. 
Fig. 9.7 Re .. r whoel cylinder components on lilter models (Sec 8) 
1 Rubber boots 2 Se'lls 3 PiS/OilS 4 Re/vm spring 
5 Wheel cylinder body 6 Bleed screw 7 OVSI cover 
1 0 MJsle r cylinder -rcmov;11 Jnd refitting 
P lace a ~wllcIH'hJe COI11~lIler benem h Ihe  mJ$le f cylinde r 10 cmch ,1ny spIlled Ihud ... Mil also place ~on,e cloth  on Ihe surrounding hodywork ;lml componems 2 Disco"nect Ihe  wirinlJ lrom the low tluid winni,,!) sw,tch  on the ,evelvoir 1,lh.1I r:ap (photo). 
3 UIlSI:f(lW lill) reservoir 1011111 cap  and dr"w out the flui(1 using  J syphon or sucl'o" l(,be <1 Unsocw ("u un'on Illl(S IOnd rlist:onncct  Ihe b,ake lines. 5 Unscrew lOud r emove  (ill) nlolUwng  nulS and washers Jnd lilt the mnster cyl",du' hom Ihe Siuds Oil Ih e  servo lmll. G Empty llin tlu,d 11010 llie con l,urlcr Jnd remove  the master cylinder 
from Ihe  enU",e  comp(lrtmeni. Io1k,ng cllre nOI 10 spill Iluid on  the bodywolk. 7 HeliuinU  's II ,eve'slIl of removJI. but on completion bleed the hydraulic syslem IIS (Iescribed In Section 15. 
10.2  Disconne cting  the low lIuid warning switch wiring 
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        Page 150 of 205

1 Chapter 9  Braki ng system 1 49 
,1  M aste r cylinder -overhaul 
With tho m
Girling  type 2 Removo  the SCleW$ and withdraw rhe fluid reservoir.  twisting i as necesS,,'y from Ihe  end  seal. 3 Remove  the twO seals afler cdraC ling the  circlip  ovor Ihe cnd seal. <1 Using II hOKagon key. unscrew Ihe relainer and hit oUllhe primary 
recuperating  valvo. Oepress Ihe primll'y piston  during Ihis procedure. 5 Exl.;'!ct  Ihe primary and secondary pistons. IOgether wi,h their associated components. noting Ihe  order of lemOlln l.  H nccessary top Ihe master cylinder on a block of wood or  use air pressure  from il foot pUIllP through the inlel porlS. G Separate  rhe primmy ,10d secondary l)is10 11S irani lha intermediilte 
sprinu . Uso  tho !inUe.s 10 remove tile  Ulilnd seDI from  the primil'Y 
r""' lon . 
The secondil'y piSlon  assembly should  ho sOfh"ated by lilting the u"mblo leaf ove , Ihe shouldered cnd 01 tho viston . Using the lingo,s. 
rr  'wo the se
spnJlg 
9 Dotach lhe villve space ,. tilking c
Teves (ATE)  type 10 Dopress  Ihe primary piston,  thon oxtrnCtlhe circlip  from the mOUlh of  th o c ylindo r and also unscrew Ille SlOp screw. 11 Extract the primary piston  componen ts  noting Ihe order 0 1 removal. followed by Ihe secondary piston componenlS. If necessary  top the 
master  cylinder on a block  of wood or  use  air pressure  from  a 1001 pump through tho inlet  ports. 12 Prise  the seals  from the pistons, nOling which way round  they are lilled. then il necessary  remove tho springs  and seals.  The prima ry 
pis ton  spring  is retained by a screw. 
Both types 13 Clean  all tho components  in  melhylated  spirits or brake fluid then 
inspec t them for  wear  and damage.  Check the cylinder bore and pistons  for scorinu and corrosion.  and if eviden t renew  the complete nI
.opair kit  of seals. 14 Di p Ihe piston and  seills in hydrilulic  Iluid then reassemble  Ihe m
convex side against Ihe shoulder  nange. Belore  refiuing the  fluid reservoi r on lhe Girling  type ch ock that the  recupera ling  valve is open wllh Ihe  prim
depressed. 
1 
2~ 
3~ 
13 
1 
2 
3 
4 5  6 
7 8 
R 
22 
21 
Fig.  9
.8 Exploded view 01 the  Girlin g master cylinder (Sec 11) 
Filler cap 9 Seal 16 Secondary piston 
Seal 10 MaSler  cylinder body 17 Seal 
Seal  !Clainer 
11 WiJslrer 18 Rell11i1er 
Fluid reservoi r 12 Reservoir relaining screw 19 Spring 
Seal 
1 3 Seal 20 Spring  fl/Miner 
Relainer 
14 Primary piSlon 21 Valve 
Primary  fCCllpCfaling  valve 
15 Spring 22 Seal 
Circlip 
10 
! 
" 1 , 
1 
I 
! 
! 
I , 
J 
,[ 
1 
I 
I 
; . 
!I ' i ;. 
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        Page 164 of 205

Chapter 10 S uspension and steering 163 
~~--,,$iJO 
~~\~ 
Fig. 10.7 Coil spri n g compressor lOo ls  (Sec 6 ) 
\. 
FiU. 1 0 .8 C o rn pressi nu  the frOllt Goil spring ( S ec 6) 
~ " / ron t stobiliser bar clamp  mountrng 
2 Mount the  strut firmly  i n ~ vice . 
3 Fit  t he  spring  compressor  tool(s)  to the coil  spring and compress the  spring until it  is juSt clear of  the  upper mounting. Milke sure tho t the 
1001 is f ully engilged with the spring. 
4  Prise off  Ihe plastic cap then unscrew Ihe pis ton nut ~nd remove 
t he  cranked 
retoiner . 
F ig . 10 .9  CU\·
ilWilY view o f th e front coil  spring nnd strut mountin g compo nents (Sec 6) 
A Shack absorbfN pis/ull B 51,,11 
5 Remove  Ihe upper 1110unling  lollowed by Ihe  corl  spring. rebOllnd 
rubber and lowe r sprrnU  seal. G The coil springs are colour· coded ,1nd II a new sprong 's being I,!led 
il muSI hilve the same colour  code. 
7 Ref itting is a  reve,sal 01 removal. but il Will be neceSS
nlll _ using  locking  fluid on its thre
nul  until Ihe weighl  of Ihe  car  is on the suspension and. when l ightening il. posilion the cranked  retainer wIth ilS twO ears al 90' to 
lhe centre.line of  Ihe CM. Where  the p iSlon rod incorpor
crrmp  the  nut 
II~nge into the 5101 
7  F ront stabiliser bar -removal 
Apply  t
he hand brake then Jack up the front  of  the  car and supporl 
on axle stands. Remove  Ihe fronl roadwheels. 
2  Working under  Ihe CM at the  Irani. knock  back the loc king tabS on the  four baits  securing  tile two f,ont ct~mps Iha t hold  the swb,hser ba r 
t o  the  frame and then undo t he  four bol tS and remove  lhe clampS 
rubber insulJtors (phOIO). 3  Remove the split pins 110m the cJstellated nu ts rewin in g the stabiliser  bar to  the Irack control arms, then undo Ihe nu ts and pull  off 
, 
I " I , , 
j 
! 
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