BRAKE MASTER CYLINDER REMOVAL

CAUTION / NOTICE / HINT

Note:

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

PROCEDURE

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

    Click here

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

    Click here

  3. REMOVE FUEL FILTER ELEMENT ASSEMBLY (for 1WW)

    1. Remove fuel filter element assembly (Click hereClick here).

  4. REMOVE WINDSHIELD WIPER MOTOR AND LINK

    1. Remove the windshield wiper motor and link (Click here).

  5. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY (for 1ZR-FAE)

    Click here

  6. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY (for 2ZR-FAE)

    Click here

  7. REMOVE OUTER COWL TOP PANEL (for 1WW)

    Click here

  8. DRAIN BRAKE FLUID

    Note:

    Wash off brake fluid immediately if it comes in contact with any painted surface.

  9. REMOVE BRAKE ACTUATOR ASSEMBLY

    1. Remove the brake actuator assembly (Click here).

  10. DISCONNECT CLUTCH TUBE (for Manual Transaxle)

    1. C200634E02

      Slide the clip and disconnect the clutch tube.

      Table 1. Text in Illustration

      *A

      for LHD

      *B

      for RHD

  11. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY

    1. C200635E02

      Disconnect the connector and detach the clamp.

      Table 2. Text in Illustration

      *A

      for LHD

      *B

      for RHD
    2. C200652E02

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

      Table 3. Text in Illustration

      *A

      for LHD

      *B

      for RHD
    3. C204970E01

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

      Table 4. Text in Illustration

      *1

      Piston
      Note:

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

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

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

      • Do not allow any foreign objects to contaminate the master cylinder piston. If a foreign object gets on the 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 piston.

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

      • Be careful not to damage the brake tubes.

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