BRAKE MASTER CYLINDER (for RHD) REMOVAL

Note

While the battery is connected, even if the engine switch is off, the brake control system activates when the brake pedal is depressed or the door courtesy switch turns on. Therefore during servicing of the brake system components, do not operate the brake pedal and open/close the doors while the battery is connected.


  1. PRECAUTION

    CAUTION:

    Be sure to read the Precaution thoroughly before servicing Click here.

    Note

    After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notice before proceeding with work Click here.

  2. REMOVE V-BANK COVER SUB-ASSEMBLY


    1. A01GMKRE01

      Using both hands, lift the rear side of the cover upwards to detach the 4 clips labeled B. Then slide the cover toward the front of the vehicle to detach the 2 clips labeled A and remove the V-bank cover sub-assembly.

      Note


      • The V-bank cover sub-assembly may be damaged if its front and rear are lifted at the same time.

      • When detaching the clips labeled A, be sure to slide the cover toward the front of the vehicle.

  3. REMOVE COWL TOP VENTILATOR LOUVER LH


    1. A01GM4S

      for LHD:

      Remove the 6 clips and cowl top ventilator louver RH.

    2. A01GI9P

      for RHD:

      Remove the 6 clips and cowl top ventilator louver LH.

  4. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  5. DISCONNECT BRAKE ACCUMULATOR PUMP CONNECTOR


    1. A01GN5S

      With the power switch off, disconnect the 2 brake accumulator pump connectors.

  6. PERFORM ACCUMULATOR ZERO DOWN


    1. Drain the brake fluid in the reservoir tank near the MIN line.

    2. Connect the intelligent tester to the DLC3 with the power switch off.

    3. Turn the power switch on (IG).

    4. Turn the intelligent tester on and enter the following menus: Chassis / ABS/VSC/TRC / Utility / ECB (Electronically Controlled Brake system) Utility / Zero Down.

      Tech Tips

      Using the intelligent tester to perform accumulator zero down causes the pressurized fluid in the accumulator to be returned to the brake fluid reservoir.

    5. When the buzzer sounds, turn the power switch off.

    6. Turn the intelligent tester off.

  7. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  8. REMOVE SKID CONTROL ECU

    Click here

  9. REMOVE SKID CONTROL ECU BRACKET

    Click here

  10. REMOVE BRAKE ACTUATOR AND BRAKE ACCUMULATOR PUMP ASSEMBLY

    Click here

  11. DISCONNECT NO. 3 RELAY BLOCK


    1. A01GIQR

      While pushing the claw of the No. 3 relay block, pull out the No. 3 relay block and disconnect it from the reservoir bracket.

      Note

      Do not allow brake fluid to contact the No. 3 relay block.

  12. REMOVE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY


    1. A01GLXTE01

      Disconnect the wire harness clamp (labeled A) from the reservoir.

    2. Detach the connector clamp (labeled B) from the reservoir bracket, and then disconnect the brake fluid level warning switch connector (labeled C).

    3. Disconnect the No. 1 brake actuator hose (labeled D) from the reservoir.

    4. A01GKWQE02
      Text in Illustration
      *1 Reservoir
      *2 Lock
      *3 Reservoir Connector

      Release the locks of the reservoir connectors. Then disconnect the No. 2 brake actuator hose (labeled E) and No. 1 reservoir hose (labeled F) from the reservoir.

      Note


      • Check for any dirt and foreign matter contamination in the reservoir and around the reservoir connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the reservoir and reservoir connector.

      • Do not use any tools to separate the reservoir and reservoir connector.

      • If the reservoir and reservoir connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the hose.

      • Put the reservoir and reservoir connector ends in plastic bags to prevent damage and dirt contamination.

    5. Remove the 2 bolts and brake fluid reservoir.

  13. REMOVE NO. 1 RESERVOIR HOSE


    1. A01GJI6E01

      Remove the hose clip (labeled A) and No. 1 reservoir hose (labeled B) from the master cylinder.

    2. Remove the hose clip (labeled C) and reservoir connector (labeled D) from the No. 1 reservoir hose (labeled B).

  14. REMOVE RESERVOIR BRACKET


    1. A01GK8N

      Remove the 3 bolts and reservoir bracket.

  15. REMOVE FRONT WHEEL

  16. REMOVE NO. 1 INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY

    Click here

  17. REMOVE BRAKE PEDAL RETURN SPRING


    1. A01GK7Z

      Remove the spring.

  18. REMOVE PUSH ROD PIN


    1. A01GKNUE05
      Text in Illustration
      *1 Push Rod Pin
      *2 Clip

      Remove the clip and push rod pin.

  19. REMOVE BRAKE MASTER CYLINDER WITH SIMULATOR ASSEMBLY


    1. A01GI6G

      Disconnect the brake stroke simulator connector.

    2. Remove the 4 nuts and brake master cylinder with simulator.

  20. REMOVE BRAKE BOOSTER GASKET


    1. A01GJJQ

      Remove the brake booster gasket from the brake master cylinder with simulator.