Removal

BRAKE: BRAKE MASTER CYLINDER: REMOVAL

NOTICE:
* Release the vacuum from the booster by depressing the brake pedal several times. Then remove the brake master cylinder sub-assembly from the brake booster assembly.
* The structure of the master cylinder allows the piston to pop out, so observe the following:
(1) for TMC Made:
* 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.
* Do not scratch or damage the circumference of the piston. For the seal to function correctly, all sliding surfaces must not have any damage.
* Do not pull out the master cylinder piston.
* When installing the master cylinder, remove the protectors for the piston and the discharge port.
* Apply the supplied grease to the outer diameter of the piston and the inner diameter of the brake booster.
(2) for TMMK Made:
* Do not hold the master cylinder by the piston. (Hold the master cylinder by its body or its reservoir while transporting it.)
* Do not pull out the master cylinder piston.
* Do not strike or pinch the master cylinder piston, and do not cause any damage to the master cylinder piston by any other means.
* 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 off.
* 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.
* Do not use any other type 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 the brake fluid leaks onto any painted surface, wash off or remove the brake fluid completely.

2. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (for 2AR-FE)

HINT
* for PZEV: Removal
* except PZEV: Removal

3. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (for 2GR-FE) Removal

4. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

5. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH Removal

6. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH Removal

7. REMOVE FRONT FENDER TO COWL SIDE SEAL LH Removal

8. REMOVE FRONT FENDER TO COWL SIDE SEAL RH Removal

9. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Removal

10. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Removal

11. REMOVE COWL TOP OUTER FRONT PANEL SUB-ASSEMBLY

(a) Disengage the clamp.

(b) Remove the 4 nuts, the 4 bolts and the cowl top outer front panel sub-assembly.

12. DISCONNECT CLUTCH RESERVOIR TUBE (for Manual Transaxle)

(a) Slide the clip and disconnect the clutch reservoir tube from the brake master cylinder sub-assembly.

13. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY (for TMC Made)

(a) Disconnect the connector.

(b) Using SST, disconnect the 6 brake lines and remove the brake master cylinder to way tube.

SST : 09023-00101

14. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY (for TMMK Made)

(a) Disconnect the connector.

(b) Using SST, disconnect the 6 brake lines and remove the brake master cylinder to way tube.

SST : 09023-38200

SST : 09023-00101