BRAKE MASTER CYLINDER(for LHD) REMOVAL

CAUTION / NOTICE / HINT

Note

Make sure to release vacuum from the brake booster assembly before removing the brake master cylinder sub-assembly from the brake booster assembly.

PROCEDURE


  1. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  2. REMOVE WATER GUARD PLATE LH (for Sedan)


    1. B00435E

      Disengage the clamp and remove the water guard plate LH.

  3. REMOVE NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for Sedan)


    1. B00441V

      Disengage the clamp and remove the No. 2 heater air duct splash shield seal.

  4. REMOVE OUTER COWL TOP PANEL (for Sedan)


    1. w/ Windshield Deicer System:


      1. B0044XH

        Disconnect the connector.

      2. Disengage the 3 clamps to separate the wire harness.

    2. B004268

      Remove the 11 bolts and outer cowl top panel.

  5. REMOVE WATER GUARD PLATE LH (for Hatchback, Wagon)


    1. B0042UF

      Disengage the clamp and remove the water guard plate LH.

  6. REMOVE NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for Hatchback, Wagon)


    1. B0044Z4

      Disengage the clamp and remove the No. 2 heater air duct splash shield seal.

  7. REMOVE OUTER COWL TOP PANEL (for Hatchback, Wagon)


    1. B0042ZG

      Remove the 11 bolts and outer cowl top panel.

  8. REMOVE NO. 1 ENGINE COVER (for 1NR-FE)

    Click here

  9. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (for 1NR-FE)

    Click here

  10. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (for 1NR-FE)

    Click here

  11. REMOVE NO. 2 CYLINDER HEAD COVER (for 1ZR-FE)

    Click here

  12. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (for 1ZR-FE)

    Click here

  13. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (for 1ZR-FE)

    Click here

  14. REMOVE NO. 2 CYLINDER HEAD COVER (for 1ZR-FAE)

    Click here

  15. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (for 1ZR-FAE)

    Click here

  16. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (for 1ZR-FAE)

    Click here

  17. REMOVE NO. 2 CYLINDER HEAD COVER (for 2ZR-FE)

    Click here

  18. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (for 2ZR-FE)

    Click here

  19. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (for 2ZR-FE)

    Click here

  20. REMOVE NO. 1 ENGINE COVER (for 1ND-TV with No. 1 Engine Cover)

    Click here

  21. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (for 1ND-TV)

    Click here

  22. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (for 1ND-TV)

    Click here

  23. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE (for 8NR-FTS)

    Click here

  24. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (for 8NR-FTS)

    Click here

  25. REMOVE NO. 1 ENGINE COVER (for 1WW)

    Click here

  26. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE ASSEMBLY (for 1WW)

    Click here

  27. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (for 1WW)

    Click here

  28. REMOVE NO. 1 FUEL FILTER PROTECTOR (for 1WW)

    for 1WW (w/ Fuel Heater Relay): Click here

    for 1WW (w/o Fuel Heater Relay): Click here

  29. REMOVE FUEL FILTER ASSEMBLY (for 1WW, 1ND-TV)

    for 1WW (w/ Fuel Heater Relay): Click here

    for 1WW (w/o Fuel Heater Relay): Click here

    for 1ND-TV: Click here

  30. DISCONNECT WIRE HARNESS (for 1ND-TV)

    Click here

  31. DISCONNECT WIRE HARNESS (for 1WW)

    Click here

  32. REMOVE GLOW PLUG RELAY ASSEMBLY (for 1WW, 1ND-TV)

    Click here

  33. REMOVE FUEL FILTER SUPPORT (for 1ND-TV)

    Click here

  34. REMOVE FUEL FILTER SUPPORT (for 1WW)

    Click here

  35. DRAIN BRAKE FLUID

    Note

    If brake fluid leaks onto any painted surface, immediately wash it off.

  36. DISCONNECT CLUTCH RESERVOIR TUBE (for Manual Transaxle)


    1. Slide the clip and disconnect the clutch reservoir tube from the brake master cylinder sub-assembly.

  37. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY


    1. B00440P

      Disengage the 3 clamps and disconnect the reservoir level switch connector.

    2. B0043O6

      Using a union nut wrench, disconnect the 2 brake lines from the brake master cylinder sub-assembly.

      Note


      • Do not damage or deform the brake lines during the removal procedure.

      • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.

    3. B0042XI

      Remove the 2 nuts and brake master cylinder sub-assembly from the brake booster assembly.

      Note


      • Do not hold the brake master cylinder sub-assembly by the master cylinder piston. Hold the brake master cylinder sub-assembly by its body or its reservoir when carrying it.

      • Do not pull out the master cylinder piston.

      • Do not strike or pinch the master cylinder piston, or cause any damage to the master cylinder piston by any other means.

      • When installing the brake master cylinder sub-assembly to the brake booster assembly, or when removing the brake master cylinder sub-assembly from the brake booster assembly, make sure that the brake master cylinder sub-assembly is kept horizontal or with its tip facing downward (the master cylinder piston is facing upward) to prevent the master cylinder piston from falling out.

      • Do not allow any foreign matter to contaminate the master cylinder piston. If any foreign matter gets on the master cylinder piston, remove it by using a piece of cloth and then apply an even layer of lithium soap base glycol grease around the circumference (sliding part) of the master cylinder piston.

    4. Remove the brake master cylinder O-ring from the brake master cylinder sub-assembly.