REMOVAL AND INSTALLATION <LHD>

caution

The master cylinder assembly cannot be disassembled. Perform the operation below with care to prevent falling-off of the piston, because structurally the piston comes off easily.

Do not remove the cover mounted on the spare master cylinder assembly until the installation work.
During the master cylinder assembly operation, handle it with the piston facing upwards.
To remove the master cylinder assembly from the brake booster assembly, depress the brake pedal several times to release the negative pressure in the brake booster assembly before removal.

If the piston comes out from the master cylinder assembly for 3.2 mm or more, do not reinsert it to use. Replace the master cylinder assembly with the new one.

Pre-removal operation

Brake fluid draining
Depress the brake pedal several times to release the vacuum pressure in the brake booster assembly.

Post-installation operation

Brake fluid refilling and air bleeding (Refer to ).
Brake pedal check and adjustment (Refer to ).

			Master cylinder removal steps
	>>F<<	·	Brake pedal stroke sensor initialization <only at installation>
		1.	Brake fluid level switch connector connection
		2.	Brake pipe connection
<<A>>	>>E<<	3.	Reservoir assembly and master cylinder assembly
	>>D<<	·	Push rod depth adjustment <only at installation>
		4.	O-ring
		5.	Reservoir cap
		6.	Pin
		7.	Reservoir assembly
		8.	Grommet
		9.	Brake fluid level switch
<<A>>	>>E<<	10.	Master cylinder assembly
			Brake booster removal steps
	>>F<<	·	Brake pedal stroke sensor initialization <only at installation>
		1.	Brake fluid level switch connector connection
		2.	Brake pipe connection
<<A>>	>>E<<	3.	Reservoir assembly and master cylinder assembly
	>>D<<	·	Push rod depth adjustment <only at installation>
		4.	O-ring
		·	Wiper link assembly (Refer to GROUP 51 - Windshield Wiper ).
		11.	Brake booster vacuum switch connector connection
		12.	Vacuum hose connection
		13.	Snap pin
		14.	Pin assembly
	>>C<<	15.	Brake booster assembly
		16.	Seal
		17.	Spacer
		18.	Brake booster vacuum switch
		19.	Grommet
			Vacuum hose removal steps
<<B>>	>>B<<	20.	Vacuum hose (integrated with the check valve)
		·	Electric motor unit inspection lid
	>>A<<	21.	Vacuum hose assembly

REMOVAL SERVICE POINTS

<<A>> RESERVOIR ASSEMBLY AND MASTER CYLINDER ASSEMBLY/MASTER CYLINDER ASSEMBLY REMOVAL

caution

The master cylinder assembly cannot be disassembled. Perform the operation with care to prevent the falling off of the piston, because structurally the piston comes off easily.
If the piston comes out from the master cylinder assembly for 3.2 mm or more, do not reinsert it to use. Replace the master cylinder assembly with the new one.

<<B>> VACUUM HOSE REMOVAL

If the vacuum hose is reused, put a paint mark to the brake booster side of the vacuum hose not to confuse the installation direction before remove the vacuum hose.

INSTALLATION SERVICE POINTS

>>A<< VACUUM HOSE ASSEMBLY INSTALLATION

caution

Be careful not to install the vacuum hose assembly to the wrong direction. If the direction is wrong, the brake booster may not work and the brake may be ineffective.

Install the vacuum hose assembly so that the check valve is in the direction as shown in the figure.

>>B<< VACUUM HOSE INSTALLATION

caution

Be careful not to confuse the installation direction of the vacuum hose. If the direction is wrong, the brake booster may not work and the brake may be ineffective.

1.If a new vacuum hose is installed, position the paint marks on the end of vacuum hose as a yellow mark faces the brake booster side and as a white mark faces the vacuum pipe side, and install the vacuum hose.

2.When the vacuum hose is reused, install it as the paint mark which was put at removal faces the brake booster side.

>>C<< BRAKE BOOSTER ASSEMBLY INSTALLATION

caution

To replace the spare brake booster assembly independently, do not adjust the push rod depth because it is set up the position where its depth does not hamper the function of the master cylinder assembly. However, if the master cylinder assembly is replaced at the same time, adjust the depth of the brake booster assembly before install the master cylinder assembly, adjust the depth of the brake booster assembly using the jig attached to the spare master cylinder assembly.

note

For the master cylinder assembly, the piston protrusion amount differs depending on the difference in processing accuracy. When the brake booster assembly is replaced independently, the pedal stroke may increase slightly, but the brake performance is not affected.

>>D<< PUSH ROD DEPTH ADJUSTMENT

caution

A jig suitable for the spare master cylinder assembly is attached. To adjust the push rod depth correctly, be sure to use the jig attached to the spare component, and don’t use it as a jig of other spare component.

Check that the push rod depth is the length (A) as shown, using the jig attached to the spare component.

2.When the push rod depth differs from the jig length, use angle nose pliers to fix the push rod at the area indicated with an arrow. Then, use the push rod adjusting socket (special tool: MB991568) to rotate the push rod leading end, and adjust the push rod depth to match with the jig length.

note

It is recommended to use the angle nose pliers that are commercially available.

>>E<< MASTER CYLINDER ASSEMBLY/RESERVOIR ASSEMBLY AND MASTER CYLINDER ASSEMBLY INSTALLATION

caution

The master cylinder assembly cannot be disassembled. Perform the operation with care to prevent the falling off of the piston, because structurally the piston comes off easily.
If the piston comes out from the master cylinder assembly for 3.2 mm or more, do not reinsert it to use. Replace the master cylinder assembly with the new one.

>>F<< BRAKE PEDAL STROKE SENSOR INITIALIZATION OPERATION

Initialize the brake pedal stroke sensor installed to the brake pedal assembly in the following procedure.

1.Disconnect the auxiliary battery (-) terminal. (Refer to GROUP 54A - Auxiliary battery

)

2.Disconnect the auxiliary battery (-) terminal and wait for 1 minute.

3.After 1 minute, connect the auxiliary battery (-) terminal. (Refer to GROUP 54A - Auxiliary battery

)