Rover 214 & 414 Service and Repair Manual - Rover club

9.5a Non-ABS master cylinder components
1 Master cylinder reservoir
2 Mounting seals
3 Secondary piston stop pin
4 Master cylinder body
2 Wipe clean the area around the brake pipe
unions on the side of the master cylinder and
place absorbent rags beneath the pipe unions
to catch any surplus fluid. Unscrew the two
union nuts and carefully withdraw the pipes.
Plug or tape over the pipe ends and master
cylinder orifices to minimise loss of brake fluid
and to prevent the entry of dirt into the
system. Wash off any spilt fluid immediately
with cold water.
3 Slacken and remove the two nuts and
washers securing the master cylinder to the
vacuum servo unit then withdraw the unit from
the engine compartment. Remove the O-ring
from the rear of the master cylinder and
discard it.
Overhaul
4 Remove the master cylinder from the
vehicle as described above and clean it
thoroughly.
5 Carefully prise the reservoir from the master
cylinder body and remove the two mounting
seals (see illustrations).
6 Prepare a clean working surface and
proceed as follows.
Non-ABS system
7 Using a wooden dowel, press the primary
piston in as far as possible and extract the
5 Spring
6 Circlip
7 Primary piston
8 Secondary piston
1 Master cylinder
reservoir
2 Mounting seals
3 Master cylinder
body
secondary piston stop pin from the reservoir
inlet port, then remove the retaining circlip.
8 Noting the order of removal and the
direction of fitting of each component,
withdraw the piston assemblies with their
springs and seals, tapping the body on to a
clean wooden surface to dislodge them. If
necessary, clamp the master cylinder body in
a vice (fitted with soft jaw covers) and use
compressed air of low pressure (applied
through the secondary circuit fluid port) to
assist the removal of the secondary piston
assembly.
9 Thoroughly clean all components using
only methylated spirit, isopropyl alcohol or
clean hydraulic fluid as a cleaning medium.
Never use mineral-based solvents such as
petrol or paraffin which will attack the
hydraulic system’s rubber components. Dry
the components immediately using
compressed air or a clean, lint-free cloth.
10 Check all components and renew any that
are worn or damaged. Check particularly the
cylinder bores and pistons. The complete
assembly should be renewed if these are
scratched, worn or corroded. If there is any
doubt about the condition of the assembly or
of any of its components, renew it. Check that
the body’s inlet and bypass ports are clear.
1689 Rover 214 & 414 Updated Version 09/97
9.5b ABS master cylinder components
4 Spring
5 Secondary piston
6 Retaining pin
7 Grub screw
8 Spring
Braking system 9•7
9 Primary piston
10 Washer
11 Circlip
12 Flat washer
13 Dust cap
11 If the assembly is fit for further use, obtain
a repair kit. Renew all seals and O-rings
disturbed on dismantling, never re-use them.
Renew also any other items included in the
repair kit.
12 On reassembly, soak the pistons and new
seals in clean hydraulic fluid. Smear clean
fluid into the cylinder bore.
13 Fit the new seals to their pistons, using
only the fingers to manipulate them into the
grooves.
14 Insert the pistons into the bore by using a
twisting motion to avoid trapping the seal lips.
Ensure that all components are refitted in the
correct order and the right way round.
15 Press the secondary piston assembly fully
up into the bore using a clean wooden dowel,
then refit the stop pin.
16 Refit the primary piston assembly, then
secure it in position with a new circlip.
17 Press the new mounting seals into the
master cylinder body and carefully refit the
reservoir ensuring that it is pressed fully into
position.
ABS system
18 Carefully prise out the dust cap from the
rear of the master cylinder body and remove
the flat washer.
19 Using a wooden dowel, press the primary
9