Master Cylinder Removal and Installation

CAUTION: Brake fluid will damage electrical connections and painted surfaces. Use shop cloths, drip pans and fender covers to prevent brake fluid from contacting these areas.

Removing/Installing Master Cylinder Assembly:

Exploded View Of Master Cylinder Assembly And Booster:

Removal:
1. Clean around reservoir cap and take out fluid with a syringe.
2. Disconnect two brake pipes from master cylinder.
3. Remove two attaching nuts and washers.
4. Remove master cylinder.

Master Cylinder Piston To Booster Piston Rod Clearance:

5. Adjust clearance of booster piston rod to master cylinder piston as follows:
NOTES:
- Before measuring clearance, push piston rod several times so as to make sure reaction disc is in place.
- Take measurement with gasket installed to master cylinder.
- Keep inside of booster at atmospheric pressure for measurement.

Fig. 4 Tool J-34873 installation:

a. Set measuring tool J-34873 on master cylinder and push pin until it contacts piston.

Fig. 5 Adjusting clearance between tool and piston rod:

b. Turn tool upside down and place on booster. Adjust booster piston rod length until rod end contacts pin head.
c. Adjust clearance by turning adjusting bolt of piston rod.

NOTE: When adjusted as above, if negative pressure is applied to booster with engine at idle, piston to piston rod clearance should become 0.1 - 0.5 mm (0.004 - 0.020 in).

Installation:
1. Install master cylinder as shown and torque attaching nuts to 10-16 Nm ( 7.5 - 11.5 ft. lb.).
2. Attach two hydraulic lines and torque flare nuts to 14-18 Nm ( 10.5 - 13.0 ft.lb.).
3. Fill reservoir with brake fluid.
4. Check brake pedal height.
5. Bleed brakes. Refer to Brakes/Service and Repair/Bleeding Procedure. Service and Repair