Master Cylinder Removal and Installation

Master Cylinder Removal and Installation

Master Cylinder and Brake Booster Components

NOTE:

- The master cylinder will lose its original performance if it is disassembled and reassembled.
If any faulty condition is found with the master cylinder, replace it rather than trying to disassemble and repair it.
- Brake fluid is extremely damaging to painted surfaces.
If brake fluid contacts a painted surface, immediately wipe it off and flush the surface thoroughly with water.

Removal

1) Clean outside of master cylinder.
2) Remove battery referring to Service and Repair Battery Removal and Installation.
3) Disconnect fluid level switch coupler (1) and clamp (3) from reservoir (2).






4) Drain brake fluid in reservoir.
5) Disconnect clutch reservoir hose from reservoir (M/T model).
6) Disconnect brake pipes (1) connected to master cylinder.
7) Remove master cylinder fixing nuts (2).
8) Remove master cylinder (3) and O-ring.






Installation

Master Cylinder Inspection
1) Install new O-ring (2) to master cylinder assembly (1).
2) Apply grease to piston rod "A".

Use specified grease in spare to master cylinder or brake booster as supply parts.
3) Install master cylinder assembly (1) to brake booster (3) and tighten master cylinder fixing nuts to specified torque.

Tightening torque
Master cylinder fixing nut (a): 18 Nm (1.8 kgf-m, 13.0 lbf-ft)





4) Connect brake pipe to master cylinder and tighten flare nuts to specified torque.

Tightening torque
Brake pipe flare nut for M10 (a): 16 Nm (1.6 kgf-m, 12.0 lbf-ft)
Brake pipe flare nut for M12 (a): 19 Nm (1.9 kgf-m, 14.0 lbf-ft)





5) Connect clutch reservoir hose to reservoir and install reservoir hose clamp (M/T model).
6) Connect fluid level switch connector and clamp.
7) Install battery referring to Service and Repair Battery Removal and Installation.
8) Fill reservoir with specified brake fluid up to its MAX level.
9) After completing the work, bleed air from brake and clutch system referring to Service and Repair Air Bleeding of Brake System
and bleed air from clutch system referring to Service and Repair Air Bleeding of Clutch System
(M/T model).
10) Check each installed parts for fluid leakage.
11) Check brake pedal for play referring to Brake Pedal Play Inspection Brake Pedal Play Inspection.
12) Perform brake test and check fluid leakage.