Brake Master Cylinder: Service and Repair
BRAKE MASTER CYLINDERCOMPONENTS (Part 1):
COMPONENTS (Part 2):
COMPONENTS (Part 3):
REMOVAL
NOTICE: The structure of the master cylinder allows the piston to pop out, so observe the following:
(a) The master cylinder requires careful handling. Do not allow the master cylinder to receive any impact, such as from being dropped. Do not reuse a master cylinder that has been dropped.
(b) Do not scratch or damage the circumference of the piston. For the seal to function correctly, all sliding surfaces must not have any damage.
(c) Do not pull out the master cylinder piston.
(d) Make sure to release the vacuum from the brake booster (by removing a vacuum hose, etc.) before removing the master cylinder from the brake booster.
(e) When installing the master cylinder, remove the protectors for the piston and the discharge port.
(f) Apply the supplied grease to the outer diameter of the piston and the inner diameter of the brake booster.
1. DRAIN BRAKE FLUID
NOTICE:
^ Stop the engine and depress the brake pedal several times until no vacuum is left in the brake booster.
^ If the brake fluid leaks onto any painted surface, wash off and remove the brake fluid completely.
2. REMOVE COOL AIR INTAKE DUCT SEAL
3. REMOVE HOOD HINGE COVER (for LH Side)
4. REMOVE HOOD HINGE COVER (for RH Side)
5. REMOVE ENGINE ROOM SIDE COVER LH
6. REMOVE ENGINE ROOM SIDE COVER RH
7. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
8. REMOVE AIR CLEANER FILTER ELEMENT SUBASSEMBLY
9. REMOVE FRONT SUSPENSION UPPER CENTER BRACE
(a) Remove the 4 nuts and the front suspension upper center brace.
10. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH
11. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH
12. REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY
13. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
14. REMOVE BRAKE MASTER CYLINDER SUBASSEMBLY
(a) Disconnect the connector.
(b) Using SST, disconnect the 6 brake lines and remove the brake master cylinder to way tube.
SST 09023-00101
(c) Remove the 2 nuts, the front brake tube way, the O-ring and the brake master cylinder sub-assembly.
INSTALLATION
1. INSTALL BRAKE MASTER CYLINDER SUBASSEMBLY
(a) Install a new O-ring, the brake master cylinder subassembly and the front brake tube way with the 2 nuts .
Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
(b) Temporarily tighten the 6 brake lines and connect the connector.
(c) Using SST, fully tighten the 6 brake lines SST 09023-00101
Torque:
without SST 15 N*m (155 kgf*cm, 11 ft.*lbf)
with SST 14 N*m (143 kgf*cm, 10 ft.*lbf)
NOTICE:
^ Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).
^ This torque value is effective when SST is parallel to a torque wrench.
2. FILL RESERVOIR WITH BRAKE FLUID
3. BLEED MASTER CYLINDER
4. BLEED BRAKE LINE
5. BLEED BRAKE ACTUATOR ASSEMBLY
6. INSPECT FLUID LEVEL IN RESERVOIR
7. CHECK FOR BRAKE FLUID LEAKS
8. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
9. INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY
10. INSTALL FRONT FENDER TO COWL SIDE SEAL LH
11. INSTALL FRONT FENDER TO COWL SIDE SEAL RH
12. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH
13. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH
14. INSTALL AIR CLEANER FILTER ELEMENT SUBASSEMBLY
15. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
16. INSTALL FRONT SUSPENSION UPPER CENTER BRACE
(a) Install the front suspension upper center brace with the 4 nuts.
Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf)
17. INSTALL ENGINE ROOM SIDE COVER LH
18. INSTALL ENGINE ROOM SIDE COVER RH
19. INSTALL HOOD HINGE COVER (for LH Side)
20. INSTALL HOOD HINGE COVER (for RH Side)
21. INSTALL COOL AIR INTAKE DUCT SEAL