REMOVAL AND INSTALLATION

Pre-removal Operation

Air Cleaner Resonator, Air Cleaner Cover, Air Cleaner Intake Duct, Air Cleaner Body Assembly Removal (Refer to GROUP 15, Air Cleaner.) <LH drive vehicles>
Engine Cover and Engine Cover Bracket Removal (Refer to GROUP 11A, Camshaft and Valve Stem Seal .) <LH drive vehicles>
Air Intake Hose Removal (Refer to GROUP 15, Air Cleaner.) <LH drive vehicles>
Canister removal (Refer to GROUP 17, Evaporative Emission Control System - Canister .) <LH drive vehicles>
Brake Fluid Draining

Post-installation Operation

Brake Fluid Supplying and Air Bleeding (Refer to .)
Canister Installation (Refer to GROUP 17, Evaporative Emission Control System - Canister .) <LH drive vehicles>
Brake Pedal Adjustment (Refer to .)
Air Intake Hose Installation (Refer to GROUP 15, Air Cleaner.) <LH drive vehicles>
Engine Cover and Engine Cover Bracket Installation (Refer to GROUP 11A, Camshaft and Valve Stem Seal .) <LH drive vehicles>
Air Cleaner Resonator, Air Cleaner Cover, Air Cleaner Intake Duct, Air Cleaner Body Assembly Installation (Refer to GROUP 15, Air Cleaner.) <LH drive vehicles>

<LH drive vehicles>

		Master cylinder removal steps
	1.	Brake fluid level switch connector
	2.	Hose clip
>>C<<	3.	Reservoir hose
	4.	Reservoir assembly
	5.	Reservoir cap
	6.	Brake fluid level switch
	7.	Brake pipe connection
	·	Brake pipe [between brake master cylinder and hydraulic unit (ABS-ECU)] (Refer to GROUP 35B, Hydraulic Unit .)
	·	Clip (LH side only) (Refer to .)
	8.	Clutch damper bracket
	9.	Brake master cylinder
	10.	Rod seal
>>B<<	·	Push rod protrusion amount check and adjustment
		Brake booster removal steps
>>A<<	11.	Vacuum hose (with built-in check valve)
	12.	Snap pin
	13.	Pin
	14.	Brake booster mounting nut
	15.	Brake booster assembly
	16.	Sealer

<RH drive vehicles>

			Master cylinder removal steps
		1.	Heat protector
		2.	Brake fluid level switch connector
		3.	Hose clip
	>>C<<	4.	Reservoir hose
		5.	Reservoir assembly
		6.	Reservoir cap
		7.	Brake fluid level switch
		8.	Brake pipe connection
<<A>>		9.	Brake master cylinder
		10.	Rod seal
	>>B<<	·	Push rod protrusion amount check and adjustment
			Brake booster removal steps
	>>A<<	11.	Vacuum hose (with built-in check valve)
		·	Inlet manifold (Refer to GROUP 15, Inlet manifold .)
		12.	Snap pin
		13.	Pin
		14.	Brake booster mounting nut
		15.	Brake booster assembly
		16.	Sealer

REMOVAL SERVICE POINT

<<A>> BRAKE MASTER CYLINDER REMOVAL

caution

Ensure that the rod seal is installed to the position (shown in the figure) of the brake master cylinder. If the rod seal is not installed, it is left inside the brake booster assembly. Be sure to remove it.

INSTALLATION SERVICE POINTS

>>A<< VACUUM HOSE CONNECTION

Insert the vacuum hose into the vacuum pipe with its white marking facing upward.
Insert the vacuum hose into the brake booster with its brown marking facing forward.

Insert the vacuum hose into the inlet manifold with its white marking facing vehicle right side.
Insert the vacuum hose into the brake booster with its blue marking facing forward.

>>B<< PUSH ROD PROTRUSION AMOUNT CHECK AND ADJUSTMENT

1.Use the vacuum pump to measure dimension "A" applying a negative pressure of 66.7 kPa to the brake booster.
Standard value (A): 11.3 - 11.7 mm

note

When a negative pressure of 66.7 kPa is not applied to the brake booster, the push rod protrusion amount (A) should be 10.3 - 10.7 mm.

2.If the protrusion amount is not within the standard value range, adjust the push rod length by turning the push rod. Use special tool push rod adjusting socket (MB991568) to turn the push rod while holding the rod spline with angle-nose pliers.

>>C<< RESERVOIR HOSE CONNECTION

1.Insert the reservoir hose into the reservoir assembly with its paint mark facing upward.
2.Insert the reservoir hose into the master cylinder with its paint mark facing upward.