Brake Master Cylinder: Service and Repair

BRAKE MASTER CYLINDER

COMPONENTS:

REMOVAL
1. PRECAUTION
2. REMOVE COOL AIR INTAKE DUCT SEAL
3. REMOVE ENGINE ROOM SIDE COVER LH
4. REMOVE ENGINE ROOM COVER SIDE RH
5. REMOVE FRONT UPPER FENDER PROTECTOR LH
6. REMOVE FRONT UPPER FENDER PROTECTOR RH
7. REMOVE ROOF DRIP SIDE FINISH MOULDING LH
8. REMOVE ROOF DRIP SIDE FINISH MOULDING RH
9. REMOVE FRONT WIPER ARM HEAD CAP
10. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH
11. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH
12. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
13. DRAIN BRAKE FLUID

NOTICE: If brake fluid leaks onto any painted surface, wash off or remove the brake fluid completely.

14. REMOVE NO. 3 ENGINE ROOM RELAY BLOCK
a. Remove the bolt, nut and No. 3 engine room relay block.

NOTICE: Cover the No. 3 engine room relay block with a shop rag or a piece of cloth to prevent brake fluid from getting on it.

15. SEPARATE CLUTCH RESERVOIR HOSE (for Manual Transmission)
a. Remove the clip and separate the clutch reservoir hose.
16. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY

a. Disengage the clamp and disconnect the warning switch connector.
b. Using SST, disconnect the 2 brake tubes from the brake master cylinder sub-assembly.
SST 09023-00101

c. Remove the 2 nuts and separate the brake actuator assembly.

d. Remove the 2 nuts and brake master cylinder subassembly from the brake booster assembly.
e. Remove the O-ring from the brake master cylinder sub-assembly.

INSPECTION
1. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD

NOTICE: Make an adjustment with no vacuum in the brake booster assembly. (Depress the brake pedal several times with the engine stopped.)

HINT:
^ Adjustment of the brake booster push rod is required when the brake master cylinder sub-assembly is replaced with a new one.
^ Adjustment is not necessary when the removed brake master cylinder sub-assembly is reused and the brake booster assembly is replaced with a new one.

a. Apply chalk to the tip of the accessory tool.

HINT: An accessory tool is enclosed with a new brake master cylinder sub-assembly.

b. Place the accessory tool on the brake booster assembly.
c. Measure the clearance between the brake booster push rod and accessory tool.
Standard clearance: 0 mm (0 inch)

HINT: Adjust the clearance in these cases:
^ If there is a clearance between the accessory tool and the shell of the brake booster (floating accessory tool), the push rod is protruding too far.
^ If the chalk does not stick on the tip of the brake booster push rod, the push rod protrusion is insufficient.

d. If the clearance is not as specified, adjust the push rod length by holding the rod using SST and turning the tip of the rod using a socket driver (7 mm, 0.28 inch).
SST 09737-00020

HINT: Check the push rod clearance again after adjustment.

INSTALLATION
1. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY
a. Install a new O-ring to the brake master cylinder sub-assembly.

b. Install the brake master cylinder sub-assembly to the booster assembly with the 2 nuts.
Torque: 12.5 Nm (127 kgf-cm, 9 ft. lbs.)

c. Install the brake actuator assembly to the actuator bracket with the 2 cap nuts.
Torque: 5.5 Nm (55 kgf-cm, 48 inch lbs.)

d. Using SST, connect the 2 brake lines to the brake master cylinder sub-assembly.
SST 09023-00101
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)
e. Engage the clamp and connect the warning switch connector.
2. CONNECT CLUTCH RESERVOIR HOSE (for Manual Transmission)
a. Connect the clutch reservoir hose with the clamp.

3. INSTALL NO. 3 ENGINE ROOM RELAY BLOCK
a. Install the No. 3 engine room relay block with the bolt and nut.
Torque: 12.5 Nm (127 kgf-cm, 9 ft. lbs.)
4. FILL RESERVOIR WITH BRAKE FLUID
5. BLEED MASTER CYLINDER
6. BLEED BRAKE LINE
7. BLEED BRAKE ACTUATOR ASSEMBLY
8. BLEED AIR FROM CLUTCH LINE (for Manual Transmission)
9. INSPECT FLUID LEVEL IN RESERVOIR
10. INSPECT FOR BRAKE FLUID LEAKAGE
11. INSTALL COWL TOP VENTILATOR LOUVER SUB ASSEMBLY
12. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH
13. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH
14. INSTALL FRONT WIPER ARM HEAD CAP
15. INSTALL ROOF DRIP SIDE FINISH MOULDING LH
16. INSTALL ROOF DRIP SIDE FINISH MOULDING RH
17. INSTALL FRONT UPPER FENDER PROTECTOR LH
18. INSTALL FRONT UPPER FENDER PROTECTOR RH
19. INSTALL ENGINE ROOM SIDE COVER LH
20. INSTALL ENGINE ROOM COVER SIDE RH
21. INSTALL COOL AIR INTAKE DUCT SEAL