Removal (to 12/2010)

BRAKE: BRAKE MASTER CYLINDER: REMOVAL

NOTICE:
* The structure of the master cylinder allows the piston to pop out, so observe the following:
(1) Release the vacuum from the booster by depressing the brake pedal several times. Then remove the brake master cylinder from the brake booster.
(2) Do not hold the master cylinder by the piston. (Hold the master cylinder by its body or its reservoir when carrying it.)
(3) Do not pull out the master cylinder piston.
(4) Do not strike or pinch the master cylinder piston, and do not cause any damage to the master cylinder piston by any other means.
(5) When installing the master cylinder to the brake booster, or when removing the master cylinder from the brake booster, make sure that the master cylinder is kept horizontal or its tip faces downward (the piston faces upward) to prevent the master cylinder piston from falling out.
(6) Do not allow any foreign objects to contaminate the master cylinder piston. If a foreign object gets on the piston, remove it by using a shop rag or a piece of cloth and then apply an even layer of lithium soap based glycol grease around the circumference (sliding part) of the piston.
(7) Do not use any other types of grease.

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 brake fluid leaks onto any painted surface, immediately wash it off.

2. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE Removal (to 12/2010)

3. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY

(a) Disconnect the connector and disengage the clamp.

(b) Using a union nut wrench (10 mm), disconnect the 6 brake lines and remove the No. 1 front brake tube from the brake master cylinder sub-assembly.

(d) Remove the O-ring from the brake master cylinder sub-assembly.