Brake Master Less Reservoir Tank Cylinder Sub-Assembly
REPLACEMENT1. DRAIN BRAKE FLUID
NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately.
2. REMOVE AIR CLEANER ASSEMBLY WITH HOSE
3. REMOVE FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER [53607A/98-99]
a. Disconnect the wire harness clamp from the brace sub-assembly (w/o VSC)
b. Disconnect the 2 wire harness clamps and ABS R/B from the brace sub-assembly (w/ VSC)
c. Remove the 4 nuts and brace sub-assembly
4. REMOVE BRAKE MASTER LESS RESERVOIR TANK CYLINDER SUB-ASSY [47207/98-81]
a. Disconnect the brake fluid level warning switch connector.
b. Slide the clip and disconnect the actuator No. 1 hose from the reservoir. (w/ VSC)
c. Using SST, remove the 2 brake lines.
SST 09023-00100
d. Remove the 2 nuts and pull out the check valve bracket and master cylinder sub-assembly
5. REMOVE BRAKE MASTER CYLINDER GASKET [47275/98-81]
6. REMOVE BRAKE MASTER CYLINDER RESERVOIR TANK STOPPER [47237A/98-81]
a. Pull out the master cylinder reservoir tank stopper.
7. REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSY [47202/98-81]
a. Pull out the master cylinder reservoir sub-assembly
8. REMOVE MASTER CYLINDER RESERVOIR GROMMET [47255/98-81]
a. Remove the 2 master cylinder reservoir grommets.
9. INSTALL MASTER CYLINDER RESERVOIR GROMMET [47255/98-81]
a. Apply the lithium soap base glycol grease on the 2 master cylinder reservoir grommets.
b. Install the 2 master cylinder reservoir grommets to the master cylinder reservoir sub-assembly
10. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSY [47202/98-81]
a. Install the master cylinder reservoir sub-assembly to the master cylinder.
11. INSTALL BRAKE MASTER CYLINDER RESERVOIR TANK STOPPER [47237A/98-81]
a. Install the master cylinder reservoir tank stopper and make sure that it is fully bit into the holes of the reservoir tank and the master cylinder grooves.
12. INSTALL BRAKE MASTER CYLINDER GASKET [47275/98-81]
a. Install a new gasket.
13. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD
NOTICE: Only when replacing the master cylinder with new one, observe the following procedures.
a. Apply chalk to the tip of an accessory tool in the supply parts.
b. Place the accessory tool to the brake booster.
c. Measure the clearance between the brake booster push rod and accessory tool.
Clearance: 0 mm (0 inch)
HINT: Adjust the clearance in following cases:
- If there is a clearance between the accessory tool and the shell of the booster (floating accessory tool), the clearance is small.
- If the chalk does not stick on the tip of the push rod, the clearance is large.
d. If the clearance is outside of the specified range, fix the push rod using SST and adjust the length of the protruding adjusting bolt.
SST 09737-00020
14. INSTALL BRAKE MASTER LESS RESERVOIR TANK CYLINDER SUB-ASSY [47207/98-81]
a. Install the master cylinder sub-assembly and check valve bracket with 2 nuts.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
b. Using SST, install the 2 brake lines to the master cylinder and actuator.
SST 09023-00100
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)
c. Connect the actuator No. 1 hose with the clip. (w/ VSC)
d. Connect the brake fluid level warning switch connector.
15. INSTALL FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER [53607A/98-99]
a. Install the brace sub-assembly with the 4 nuts.
Torque: 80 Nm (815 kgf-cm, 59 ft. lbs.)
b. Connect the wire harness clamp to the brace sub-assembly (w/o VSC)
c. Connect the ABS R/B and 2 wire harness clamps to the brace sub-assembly (w/ VSC)
16. INSTALL AIR CLEANER ASSEMBLY WITH HOSE
17. FILL RESERVOIR WITH BRAKE FLUID
18. BLEED MASTER CYLINDER
SST 09023-00100
19. BLEED BRAKE LINE
20. CHECK FLUID LEVEL IN RESERVOIR
21. CHECK BRAKE FLUID LEAKAGE