How to Install a Master Cylinder on a KIA Sportage

Written by kevinm
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Kia Motors first introduced the Sportage in 1995. After discontinuing the model in 2002, Kia brought it back in a completely new and improved configuration in 2005. The master cylinder on the Sportage is a key component of the braking system. When the brake pedal is depressed, two pistons inside the master cylinder move in a way that supplies the hydraulic pressure that activates the brakes. At some point, you may need to remove and replace the master cylinder in your Sportage. The job can be challenging, but you should be able to do it yourself with a bit of time and the right tools.

Skill level:
Moderately Challenging

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Things you need

  • Wrenches
  • Sockets
  • Rags
  • Syringe or baster
  • Brake fluid

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    Removing the Master Cylinder

  1. 1

    Remove the two air cleaner mounting bolts from the air cleaner mounting bracket and air cleaner body, using an appropriately sized wrench or socket. Remove the air cleaner.

  2. 2

    Locate the master cylinder. It is attached to the brake booster, which is a dome-shaped housing located on the firewall at the rear of the engine compartment. You can recognise the master cylinder assembly by the brake fluid filler cap located on the master cylinder reservoir.

  3. 3

    Disconnect the brake fluid level switch connector. This is a wire connector on the bottom of the cylinder. Grasp the connector firmly and pull it straight off.

  4. 4

    Remove the master cylinder reservoir cap. Grasp it firmly, twist it left one-quarter turn and lift it straight off. Remove the brake fluid from the master cylinder reservoir with a syringe or baster. If the brake fluid is clean, save it a clean container for reuse.

  5. 5

    Disconnect the two brake lines from the bottom of master cylinder. Cover the joints between the brake lines and the master cylinder with rags or shop towels to catch spills of any residual brake fluid.

  6. 6

    Remove the two mounting nuts and washers that secure the master cylinder to the booster housing, using an appropriately sized wrench or socket.

  7. 7

    Remove the master cylinder from the brake booster. Grasp it with your hands and carefully pull it straight off. Be careful not to bend or damage the brake lines when removing the master cylinder.

    Installing the Master Cylinder

  1. 1

    Secure the master cylinder to the brake booster using the two nuts and washers.

  2. 2

    Connect the two brake lines and the brake fluid level sensor connector.

  3. 3

    Fill the brake reservoir with brake fluid and replace the reservoir cap.

  4. 4

    Replace the air cleaner and reattach the two air cleaner mounting bolts.

  5. 5

    Bleed the brake system to remove any air bubbles that might be trapped in the brake lines.

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