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REMOVAL AND INSTALLATION
 
 
caution
  • The master cylinder assembly cannot be disassembled. Perform the operation below with care to prevent falling-off of the piston, because structurally the piston comes off easily.
    • Do not remove the cover mounted on the master cylinder assembly (service parts) until the installation work.
    • During the master cylinder assembly operation, handle it with the piston facing upwards.
    • To remove the master cylinder assembly from the brake booster assembly, depress the brake pedal several times to release the negative pressure in the brake booster assembly before removal.
  • If the piston moves 3.2 mm (0.13 inch) or more by pushing it, replace the master cylinder assembly with a new one.
  • Do not damage the piston by impact, pinching, and so on.
  • Do not touch the piston directly by hand. To handle it, hold the body section of the master cylinder assembly.
  • Do not allow foreign matters to adhere to the piston. If foreign matter adheres to it, remove the foreign matter carefully so that the piston does not come off, using a new dry rag. Do not use water or detergent.
Pre-removal Operation
  • Brake Fluid Draining
  • Battery Removal (Refer to GROUP 54A - Battery )
Post-installation Operation
  • Battery Installation (Refer to GROUP 54A - Battery )
  • Brake Fluid Supplying and Air Bleeding (Refer to )
  • Brake Pedal Adjustment (Refer to )
Removal steps
1.Brake line heat protector
2.Heat protector
3.Brake fluid level switch connector
4.Brake pipe connection
5.Pin
6.Reservoir cap
7.Reservoir filter
8.Reservoir assembly
9.Reservoir seal
10.Brake fluid level switch
<<A>>>>C<<11.Brake master cylinder assembly
>>B<<•Push rod depth adjustment <only at installation>
12.O-ring
13.Brake vacuum sensor connector
14.Brake vacuum sensor
15.Grommet
16.Hose clip
17.Clip
>>A<<18.Vacuum hose (with built-in check valve)
19.Hose clip
20.Vacuum hose
21.Cable band
22.Vacuum pipe
23.Snap pin
24.Clevis pin
<<B>>25.Brake booster assembly
26.Sealer
 
 
REMOVAL SERVICE POINT
 
 
<<A>> MASTER CYLINDER ASSEMBLY REMOVAL
caution
  • The master cylinder assembly cannot be disassembled. Perform the operation with care to prevent the falling off of the piston, because structurally the piston comes off easily.
  • If the piston moves 3.2 mm (0.13 inch) or more by pushing it, replace the master cylinder assembly with a new one.
 
 
<<B>> BRAKE BOOSTER ASSEMBLY REMOVAL
Disconnect the engine from the engine mounting. Lower the front of the engine to remove its.
 

 
 
INSTALLATION SERVICE POINT
 
 
>>A<< VACUUM HOSE (WITH BUILT-IN CHECK VALVE) CONNECTION
Install the vacuum hose (with built-in check valve) with its marking located as shown in the figure.
 

 
 
>>B<< PUSH ROD DEPTH ADJUSTMENT
1.
cautionWhen replacing the master cylinder assembly with the new one, the push rod depth must be adjusted using the adjustment jig attached to the service parts. When re-installing the removed master cylinder assembly, the adjustment is not necessary.
Check that the push rod depth (A) and the length of the adjustment jig attached to the service parts (A') are equal (A = A').
2. When the push rod depth differs from the jig length, use angle nose pliers to fix the push rod at the area indicated with an arrow. Then, use the push rod adjusting socket (special tool: MB991568) to rotate the push rod leading end, and adjust the push rod depth to match with the jig length.
noteIt is recommended to use the angle nose pliers that are commercially available.
 

 
 
>>C<< MASTER CYLINDER ASSEMBLY INSTALLATION
caution
  • The master cylinder assembly cannot be disassembled. Perform the operation with care to prevent the falling off of the piston, because structurally the piston comes off easily.
  • If the piston moves 3.2 mm (0.13 inch) or more by pushing it, replace the master cylinder assembly with a new one.