BRAKE MASTER CYLINDER(for LHD) REMOVAL

CAUTION / NOTICE / HINT

PROCEDURE

1. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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2. REMOVE WATER GUARD PLATE LH (for Sedan)

   1. 

      Disengage the clamp and remove the water guard plate LH.

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

   1. 

      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. 

         Disconnect the connector.

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

   2. 

      Remove the 11 bolts and outer cowl top panel.

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

   1. 

      Disengage the clamp and remove the water guard plate LH.

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

   1. 

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

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

   1. 

      Remove the 11 bolts and outer cowl top panel.

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

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

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

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

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

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

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

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

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

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

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

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

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

    w/o Glow Plug Controller:Click here

    w/ Glow Plug Controller:Click here

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

    w/o Glow Plug Controller:Click here

    w/ Glow Plug Controller:Click here

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

    w/o Glow Plug Controller:Click here

    w/ Glow Plug Controller:Click here

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

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

    Click hereClick here

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

    Click hereClick here

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

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

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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)

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31. DISCONNECT WIRE HARNESS (for 1WW)

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

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

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34. REMOVE FUEL FILTER SUPPORT (for 1WW)

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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. 

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

    2. 

       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. 

       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.