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. PRECAUTION

    Note:

    After turning the ignition 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 notices before proceeding with work.

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  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note:

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

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  3. REMOVE FRONT WIPER MOTOR AND LINK ASSEMBLY

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  4. REMOVE FRONT NO. 1 VENTILATOR SEAL

    1. C302733

      Disengage the clamp and remove the front No. 1 ventilator seal.

  5. REMOVE FRONT AIR SHUTTER SEAL RH

    1. C302734

      Remove the 2 clips and front air shutter seal RH.

  6. REMOVE OUTER COWL TOP PANEL

    1. C302735

      Disengage the 2 clamps to separate the wire harness.

    2. C302736

      Remove the 9 bolts and outer cowl top panel.

  7. REMOVE BATTERY

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  8. REMOVE BATTERY CLAMP SUB-ASSEMBLY

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  9. DRAIN BRAKE FLUID

    Note:

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

  10. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY

    1. C302737

      Disconnect the reservoir level switch connector.

    2. C302738

      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.

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

    3. C302739

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

      Note:

      • The brake master cylinder sub-assembly requires careful handling. Do not allow the brake master cylinder sub-assembly to receive any impact, such as from being dropped. Do not reuse a brake master cylinder sub-assembly that has been dropped.

      • 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.

      • Do not use any other type of grease or fluid.

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

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