Diesel Data: Automotive Repair

Removal and Installation












REMOVAL
1. REMOVE AIR CLEANER COVER WITH AIR CLEANER HOSE
2. DISCONNECT LEVEL WARNING SWITCH CONNECTOR
3. TAKE OUT FLUID WITH SYRINGE

NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately.

4. w/ VSC: REMOVE BRAKE HOSE





5. DISCONNECT BRAKE LINES
Using SST, disconnect the 4 brake lines.
SST 09023-00100 (ABS only, w/ VSC) 09751-36011 (w/ TRAC)
Torque:
12 mm nut: 20 Nm (200 kgf-cm, 14 ft. lbs.)
10 mm nut: 15 Nm (155 kgf-cm, 11 ft. lbs.)





6. REMOVE MASTER CYLINDER
Remove the 2 nuts, and pull out the 2-way, master cylinder and gasket.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)

INSTALLATION
Installation is in the reverse order of removal.

HINT:
^ Before installation, adjust length of brake booster push rod.
Service and Repair

^ After installation, fill brake reservoir with brake fluid and bleed brake system.
Brake Bleeding

^ Check for leaks, check and adjust brake pedal.
Testing and Inspection