REMOVAL AND INSTALLATION <LHD>


<MASTER CYLINDER AND BRAKE BOOSTER>


Pre-removal operation
  • Brake Fluid Draining
  • Air Cleaner Assembly Removal (Refer to GROUP 15 - Air Cleaner <4A9>, <4B1> or <4N1>).

 Post-installation operation
  • Air Cleaner Assembly Installation (Refer to GROUP 15 - Air Cleaner <4A9>, <4B1> or <4N1>).
  • Brake Fluid Refilling and Air Bleeding.




Master cylinder removal steps


1.
 Brake fluid level switch connector


2.
 Reservoir cap


3.
 Brake pipe connection

>>B<<
 ·
 Bleeding of master cylinder assembly (only at installation)


4.
 Reservoir hose connection <M/T>


5.
 Master cylinder mounting nut


6.
 Reservoir assembly and master cylinder assembly


7.
 Torx bolt


8.
 Reservoir assembly


9.
 O-ring


10.
 Master cylinder assembly



Brake booster removal steps


1.
 Brake fluid level switch connector


3.
 Brake pipe connection

>>B<<
 ·
 Bleeding of master cylinder assembly (only at installation)


4.
 Reservoir hose connection <M/T>


5.
 Master cylinder mounting nut


6.
 Reservoir assembly and master cylinder assembly


·
 Fuel vapour canister (Refer to GROUP 17 - Canister ) <4A9, 4B1>


·
 Fuel filter bracket and fuel filter assembly (Refer to GROUP 13C - Fuel filter ) <4N1>


11.
 Vacuum sensor connector connection <Vehicles with ASG>


12.
 Vacuum sensor <Vehicles with ASG>

>>A<<
 13.
 Vacuum hose connection


14.
 Hose clip


15.
 Check valve


16.
 Dash panel heat protector


17.
 Brake fluid line clip


18.
 Brake pipe and brake fluid line clip connection


19.
 Brake pipe connection


20.
 Brake fluid line clip


21.
 Brake fluid line bracket


22.
 Front harness connection


23.
 Front harness connection <4A9, 4B1>


24.
 Snap pin


25.
 Pin assembly


26.
 Brake booster mounting nut


27.
 Brake booster assembly


28.
 Seal

<VACUUM HOSE AND VACUUM PIPE>



Removal steps

>>A<<
 1.
 Vacuum hose


2.
 Hose clip

>>A<<
 3.
 Vacuum hose


4.
 Hose clip


5.
 Vacuum pipe <4N1>


6.
 Emission vacuum hose connection <4B1>


7.
 Vacuum pipe assembly <4A9, 4B1>


8.
 Clamp <4N1>

INSTALLATION SERVICE POINTS

>>A<< VACUUM HOSE INSTALLATION



Align the mark as shown in the figure to assemble the vacuum hose.

>>B<< BLEEDING OF MASTER CYLINDER ASSEMBLY
When removed the master cylinder assembly, bleed the master cylinder in the following procedure to make bleeding of the brake pipeline easier (When no brake fluid is in the master cylinder).
1.Fill the brake fluid reservoir with the brake fluid.
2.Depress and hold the brake pedal.

3.Another operator closes the master cylinder outlets with his fingers.
4.In this condition, release the brake pedal.
5.Repeat Steps 2 to 4 for 3 or 4 times to fill the master cylinder with the brake fluid.