Brake Master Cylinder: Service and Repair
BRAKE MASTER CYLINDER SUB-ASSEMBLYOVERHAUL
1. DRAIN BRAKE FLUID
NOTICE: Wash brake fluid off immediately if it adheres to any painted surface.
2. REMOVE FRONT WIPER ARM HEAD CAP
3. REMOVE FR WIPER ARM & BLADE ASSEMBLY LH
4. REMOVE FR WIPER ARM & BLADE ASSEMBLY RH
5. REMOVE HOOD TO COWL TOP SEAL
6. REMOVE COWL TOP VENTILATOR LOUVER LH
7. REMOVE WINDSHIELD WIPER MOTOR & LINK ASSEMBLY
8. REMOVE COWL TOP PANEL SUB-ASSEMBLY OUTER
a. Remove the 7 bolts and cowl top panel sub-assembly outer.
9. REMOVE COWL WATER EXTRACT HOSE NO.1
a. Remove the clip and water extract hose No.1.
10. REMOVE COWL BODY MOUNTING BRACKET LOWER LH
a. Remove a bolt and body mounting bracket lower LH.
11. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
12. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY
a. Using SST, disconnect the 2 brake tubes from the master cylinder sub-assembly.
SST 09023-00101
b. Using SST, disconnect the 2 brake tubes from the No.1 way.
SST 09023-00101
c. Remove the clips and disconnect the 2 reservoir tubes from the master cylinder sub-assembly.
d. Remove the 2 nuts, and pull out the master cylinder sub-assembly and No.1 way.
13. REMOVE UNION
a. Remove the stopper screw and master cylinder union.
b. Remove the 2 grommets from the master cylinder sub-assembly.
14. REMOVE BRAKE MASTER CYLINDER KIT
a. Hold the master cylinder sub-assembly in a vise with the 2 aluminum plates in between.
b. Remove the O-ring from the master cylinder sub-assembly.
c. Push in the piston and remove the snap ring using snap ring pliers.
NOTICE: When pushing in the piston, the fluid left in the cylinder may spatter.
d. Push in the piston and remove the piston stopper bolt and gasket.
e. Remove the No.1 piston from the master cylinder body by pulling it straight out.
NOTICE: Do not scratch the inside of the cylinder body.
f. Tap the flanged part against wooden blocks until the end of the No.2 piston comes out. When the end of the No.2 piston comes out, pull out the No.2 piston straight from the master cylinder body.
NOTICE: Do not scratch the inside of the cylinder body.
15. INSPECT BRAKE MASTER CYLINDER
a. Check the inside of the brake master cylinder for scratch.
HINT: Replace the master cylinder sub-assembly if necessary.
16. INSTALL BRAKE MASTER CYLINDER KIT
a. Placing aluminum plates between the vise and the master cylinder sub-assembly, place the master cylinder sub-assembly in the vise.
b. Apply lithium soap base glycol grease to the rubber part as shown in the illustration.
c. Install the No.1 and No.2 pistons to the master cylinder body.
NOTICE:
- Install the piston straight carefully not to give any damage to the inside of the cylinder.
- Do not damage the lip of the cylinder cup.
d. Push in the piston and install a new gasket and a new piston stopper bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
e. Install the hole snap ring using snap ring pliers with the piston pushed in.
NOTICE: Do not scratch the inside of the cylinder body.
f. Apply lithium soap base glycol grease to a new O-ring.
g. Install the O-ring to the master cylinder body.
17. INSTALL UNION
a. Apply lithium soap base glycol grease and silicon grease to the 2 grommets as shown in the illustration.
b. Install the 2 grommets to the master cylinder body.
c. Install the master cylinder union with the stopper screw.
18. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD
a. Set SST on the master cylinder and lower the rod of the SST until it slightly touches the piston.
SST 09737-00013
b. Apply chalk to the flat tip of the SST rod. Turn the SST upside down and measure the clearance between the brake booster push rod and the SST.
Clearance: 0 mm (0 inch)
HINT: If there is a clearance between the SST main body and the shell of the brake booster, 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.
c. If the clearance is not within the standard, adjust the length by holding the rod using SST and turning the tip of the rod using a socket driver (7 mm).
SST 09737-00020
HINT: Check the push rod clearance again after adjustment.
19. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY
a. Install the master cylinder sub-assembly and No.1 way with the 2 nuts..
Torque: 12.5 Nm (127 kgf-cm, 9 ft. lbs.)
b. Connect the 2 reservoir tubes to the master cylinder sub-assembly with the clips.
c. Using SST, connect the 2 brake tubes to the No.1 way.
SST 09023-00101
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)
d. Using SST, connect the 2 brake tubes to the master cylinder sub-assembly.
SST 09023-00101
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)
20. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
21. INSTALL COWL BODY MOUNTING BRACKET LOWER LH
a. Install the body mounting bracket lower LH with a bolt.
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)
22. INSTALL COWL WATER EXTRACT HOSE NO.1
a. Install the water extract hose No.1 with the clip.
23. INSTALL COWL TOP PANEL SUB-ASSEMBLY OUTER
a. Install the cowl top panel sub-assembly outer with the 7 bolts.
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)
24. FILL RESERVOIR WITH BRAKE FLUID
25. BLEED MASTER CYLINDER
SST 09023-00101
26. BLEED BRAKE LINE
27. CHECK FLUID LEVEL IN RESERVOIR
28. CHECK FOR BRAKE FLUID LEAKAGE
29. INSTALL WINDSHIELD WIPER MOTOR & LINK ASSEMBLY
30. INSTALL COWL TOP VENTILATOR LOUVER LH
31. INSTALL HOOD TO COWL TOP SEAL
32. INSTALL FR WIPER ARM & BLADE ASSEMBLY RH
33. INSTALL FR WIPER ARM & BLADE ASSEMBLY LH
34. INSTALL FRONT WIPER ARM HEAD CAP