Antilock Brake (ABS) System

REMOVAL

Disconnect The Brake Lines From Master Cylinder:

1. Disconnect Level Warning Switch connector.
2. Draw out fluid with syringe.

CAUTION: Do not let brake fluid remain on a painted surface. Wash it off immediately.

3. Disconnect brake lines.
Using Special Service Tool (SST) # 09023-00100, disconnect the brake lines.
Torque: 15 Nm (155 kg.cm, 11 ft.lbs.)
4. Remove Master Cylinder.

Master Cylinder Removal:

Remove the 3 nuts and pull out the clamp, check valve bracket, Master Cylinder and gasket.
Torque: 13 Nm (130 kg.cm, 9 ft. lbs.)

Master Cylinder Components:

DISASSEMBLY

Master Cylinder Boot Removal:

1. Remove Master Cylinder boot.
Using a screwdriver, remove the Master Cylinder boot.

ASSEMBLY CAUTION: Facing the UP mark on the Master Cylinder boot upwards, install the cylinder boot to the Master Cylinder.

2. Remove reservoir cap and strainer.
3. Remove reservoir.
Remove the set screw and pull out the reservoir.
Torque: 1.7 Nm (17.5 kg.cm, 15.2 inch lbs.)
4. Remove 2 grommets.
5. Place cylinder in vise.
6. Remove no.2 piston stopper bolt.
Using a screwdriver, push the pistons in all the way and remove the No.2 piston stopper bolt and gasket.

NOTE: Tape the screwdriver tip before use.

Torque: 10 Nm (100 kg.cm, 7 ft.lbs.)
7. Remove 2 pistons.

Master Cylinder Pistons Removal:

(a) Push in the piston with a screwdriver and remove the snap ring with snap ring pliers.

NOTE: Tape the screwdriver tip before use.

(b) Remove the No.1 piston and spring by hand, pulling straight out, not at an angle.

CAUTION: If pulled out and installed at an angle, there is a possibility that the cylinder bore could be damaged.

ASSEMBLY CAUTION: Be careful not to damage the rubber lips on the pistons.

Master Cylinder Piston Removal:

(c) Place a rag and 2 wooden blocks on the work table and lightly tap the cylinder flange against the block edges until the piston drops out of the cylinder.

NOTE: Make sure the distance (A) from the rag to the top of the blocks is at least 100 mm (3.94 inch).

COMPONENTS INSPECTION

NOTE: Clean the disassembled parts with compressed air.

1. Inspect cylinder bore for rust or scoring.
2. Inspect cylinder for wear or damage.
If necessary, clean or replace the cylinder.

ASSEMBLY
Assembly is in the reverse order of disassembly.

ASSEMBLY CAUTION: Apply lithium base glycol grease to the rubber parts indicated by the arrows in the EXPLODED VIEW.

INSTALLATION
Installation is in the reverse order of removal.
Before installation, adjust length of Brake Booster push rod.
After installation, fill brake reservoir with brake fluid, bleed brake system. Service and Repair
Check for leaks and check and adjust Brake Pedal.