REMOVAL AND INSTALLATION <LHD>


MASTER CYLINDER AND BRAKE BOOSTER


caution Do not touch the push rod in the brake booster because it is already adjusted.
Pre-removal operation
  • Brake Fluid Draining
  • Air Cleaner Assembly Removal (Refer to GROUP 15 - Air Cleaner <4B1>, <6B3>).

 Post-installation operation
  • Air Cleaner Assembly Installation (Refer to GROUP 15 - Air Cleaner <4B1>, <6B3>).
  • Brake Fluid Refilling and Air Bleeding.




Master cylinder removal steps


1.
 Brake fluid level switch connector connection


2.
 Reservoir cap


3.
 Brake pipe connection

>>B<<
 ·
 Bleeding of master cylinder assembly (only at installation)


4.
 Master cylinder mounting nuts


5.
 Reservoir assembly and master cylinder assembly


6.
 Torx bolt


7.
 Reservoir assembly


8.
 O-ring


9.
 Master cylinder assembly



Brake booster removal steps


1.
 Brake fluid level switch connector connection


3.
 Brake pipe connection

>>B<<
 ·
 Bleeding of master cylinder assembly (only at installation)


4.
 Master cylinder mounting nuts


5.
 Reservoir assembly and master cylinder assembly

>>A<<
 10.
 Vacuum hose connection


11.
 Hose clip


12.
 Check valve


13.
 Snap pin


14.
 Pin assembly


15.
 Brake booster mounting nut


16.
 Brake booster assembly


17.
 Seal

VACUUM HOSE AND VACUUM PIPE <4B1>



Removal steps

>>A<<
 1.
 Vacuum hose


2.
 Hose clip

>>A<<
 3.
 Vacuum hose


4.
 Hose clip


5.
 Emission vacuum hose connection


6.
 Vacuum pipe assembly

INSTALLATION SERVICE POINTS <4B1>

>>A<< VACUUM HOSE INSTALLATION

Align the mark as shown in the figure to assemble the vacuum hose.

>>B<< BLEEDING OF MASTER CYLINDER ASSEMBLY
When removed the master cylinder assembly, bleed the master cylinder in the following procedure to make bleeding of the brake pipeline easier (When no brake fluid is in the master cylinder).
1.Fill the brake fluid reservoir with the brake fluid.
2.Depress and hold the brake pedal.

3.Another operator closes the master cylinder outlets with his fingers.
4.In this condition, release the brake pedal.
5.Repeat Steps 2 to 4 for 3 or 4 times to fill the master cylinder with the brake fluid.

VACUUM HOSE AND VACUUM PIPE <6B3>



Removal steps

>>A<<
 1.
 Vacuum hose


2.
 Hose clip


3.
 Clamp

INSTALLATION SERVICE POINT <6B3>

>>A<< VACUUM HOSE INSTALLATION

Align the mark as shown in the figure to assemble the vacuum hose.