BRAKE MASTER CYLINDER(for LHD) REMOVAL

CAUTION / NOTICE / HINT

Note

While the battery is connected, even if the power 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 or open/close the doors while the battery is connected.

PROCEDURE


  1. PRECAUTION

    CAUTION:

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

    Note

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

  2. REMOVE V-BANK COVER SUB-ASSEMBLY

    Click here

  3. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  4. DISCONNECT BRAKE ACCUMULATOR PUMP CONNECTOR


    1. A000VL6

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

  5. 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.

  6. REMOVE LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY (w/ Spare Tire)

    Click here

  7. REMOVE DECK BOARD ASSEMBLY (w/o Spare Tire)

    Click here

  8. REMOVE DECK TRIM SIDE BOARD LH (w/o Spare Tire)

    Click here

  9. REMOVE BATTERY SERVICE HOLE COVER LH

    Click here

  10. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL


    1. Disable the AUTO TILT AWAY function by changing the customize parameter Click here.

      Note

      Record the current customize parameter setting (whether the AUTO TILT AWAY function is enabled or disabled) in order to restore the current setting after finishing the operation.

      Tech Tips

      Performing the above operation causes the AUTO TILT AWAY function to be disabled when the power switch is turned off.

    2. Turn the power switch ON (IG). Operate the tilt and telescopic switch to fully extend and lower the steering column.

    3. Turn the power switch off and disconnect the cable from the negative (-) battery terminal.

      Note

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

  11. DISCONNECT NO. 1 MOTOR COOLING PIPE

    Click here

  12. REMOVE SKID CONTROL ECU

    Click here

  13. REMOVE SKID CONTROL ECU BRACKET

    Click here

  14. REMOVE BRAKE ACTUATOR AND BRAKE ACCUMULATOR PUMP ASSEMBLY

    Click here

  15. DISCONNECT NO. 3 RELAY BLOCK

    Click here

  16. REMOVE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY


    1. Disconnect the wire harness clamp from the reservoir.

      A000W6BE01
      Text in Illustration
      *1 Reservoir
      *2 Lock
      *3 Reservoir Connector

    2. Detach the connector clamp from the reservoir bracket, and then disconnect the brake fluid level warning switch connector.

    3. Disconnect the No. 1 brake actuator hose from the reservoir.

    4. Release the locks of the reservoir connectors. Then disconnect the No. 2 brake actuator hose (labeled A) and No. 1 reservoir hose (labeled B) 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.

  17. REMOVE NO. 1 RESERVOIR HOSE


    1. A000TXK

      Remove the hose clip and No. 1 reservoir hose from the master cylinder.

    2. Remove the hose clip and reservoir connector from the No. 1 reservoir hose.

  18. REMOVE RESERVOIR BRACKET


    1. A000XPI

      Remove the 3 bolts and reservoir bracket.

  19. REMOVE FRONT WHEEL

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

    Click here

  21. REMOVE BRAKE PEDAL RETURN SPRING

    Click here

  22. REMOVE PUSH ROD PIN

    Click here

  23. REMOVE BRAKE MASTER CYLINDER WITH SIMULATOR ASSEMBLY


    1. A000UW9

      Disconnect the brake stroke simulator connector.

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

  24. REMOVE BRAKE BOOSTER GASKET


    1. A000XP2

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