Brake Master Cylinder Assembly (W/ VSC)

BRAKE MASTER CYLINDER ASSEMBLY (W/ VSC)











COMPONENTS

OVERHAUL

NOTICE: Before starting the work, make sure that the ignition switch is OFF and depress the brake pedal more than 20 times.

HINT: When pressure in the accumulator is released, reaction force becomes lighter and stroke becomes longer.

NOTICE:
- As high pressure is applied to the brake actuator tube No.1, never deform it.
- Do not turn the ignition switch to ON until the work is completed.

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. DRAIN BRAKE FLUID

NOTICE: Immediately wash off any brake fluid off immediately that comes into contact with a painted surface.

3. REMOVE FRONT FLOOR FOOTREST
4. REMOVE FRONT DOOR SCUFF PLATE LH
5. REMOVE COWL SIDE TRIM BOARD LH
6. REMOVE INSTRUMENT PANEL UNDER TRAY (AUTOMATIC TRANSAXLE)
7. REMOVE INSTRUMENT PANEL HOLE COVER (MANUAL TRANSAXLE)
8. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER NO.1
9. SEPARATE DRIVER SIDE JUNCTION BLOCK
10. SEPARATE MASTER CYLINDER PUSH ROD CLEVIS





11. REMOVE BRAKE MASTER CYLINDER ASSEMBLY
a. Disconnect the 3 connectors from the brake master cylinder.





b. Using SST, disconnect the 4 brake lines from the brake master cylinder.
SST 09023-00101





c. Use tags or labels to identify the place to reconnect each line.





d. Remove the 4 nuts and pull out the brake master cylinder.
e. Remove the brake booster gasket.





12. REMOVE BRAKE ACTUATOR BRACKET NO.1
a. Using a hexagon wrench (5 mm), remove the screw and brake actuator bracket No.1.





b. Using a screwdriver, remove the fluid level warning switch connector.





13. REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY
a. Remove the screw from the master cylinder reservoir.





b. Using a pin punch and hammer, remove the pin from the master cylinder reservoir.
c. Pull out the master cylinder reservoir.
d. Remove the 3 grommets.
e. Remove the cap.





14. REMOVE BRAKE ACTUATOR HOSE
a. Using needle-nose pliers, slide the 2 clips.
b. Remove the brake actuator hose.





15. REMOVE BRAKE ACTUATOR TUBE NO.1
a. Using SST, remove the brake actuator tube No.
1. SST 09023-00101





16. REMOVE BRAKE BOOSTER W/ACCUMULATOR PUMP ASSEMBLY
a. Using a screwdriver, remove the 2 plugs.





b. Remove the 2 screws and pull the wire harness.





c. Using a screwdriver, remove the clip.





d. Remove the brake booster w/ accumulator pump assembly.





e. Using a hexagon wrench (4 mm), remove the 2 pins. Remove the 2 bushes and 2 collars from the brake booster w/ accumulator pump assembly.





17. REMOVE BRAKE ACTUATOR BRACKET
a. Using a hexagon wrench (5 mm), remove the screw and brake actuator bracket.





18. REMOVE BRAKE BOOSTER PUMP BRACKET
a. Using a hexagon wrench (5 mm), remove the 2 screws and brake booster pump bracket.
b. Remove the bush from the brake booster pump bracket.
19. REMOVE MASTER CYLINDER PUSH ROD CLEVIS
a. Loosen the lock nut on the brake master cylinder side, and then remove the rod operating adapter and lock nut.
b. Loosen the lock nut on the rod operating adapter, and then remove the push rod clevis and lock nut.
20. REMOVE MASTER CYLINDER BOOT





21. REMOVE PISTON
a. Which pressing in the piston with a screwdriver, use a pin or equivalent to push the C-ring from the hole in the master cylinder body. Then remove the snap ring with another screwdriver.
b. Remove the piston by pulling it straight out, not at an angle.

NOTICE:
- If the piston is pulled out at an angle, there is a possibility that the cylinder bore could be damaged.
- Be careful not to damage the rubber lips on the piston when reassembling.





22. REMOVE MASTER CYLINDER SOLENOID
a. Remove the 6 bolts.
b. Remove the master cylinder solenoid and the gasket.





23. REMOVE BRAKE BOOSTER ACCUMULATOR ASSEMBLY
a. Place the brake booster w/ accumulator pump assembly in a vise with a cloth.
b. Using a socket wrench (17 mm), remove the brake booster accumulator.
c. Remove the brake booster accumulator pipe, compression spring and O-ring.





24. INSPECT BRAKE BOOSTER PUMP ASSEMBLY
a. Connect the positive (+) lead from the battery to the red cable of the pump, and the negative (-) lead to the black cable.
b. Check the brake booster pump operation.
OK: Operation sound is heard.





25. DISPOSE OF BRAKE BOOSTER ACCUMULATOR ASSEMBLY
a. Place the brake booster accumulator in a vise and cover it with a cloth.
b. Slowly cut a hole on the brake booster accumulator side in the A portion shown in the illustration on the left. And discharge the gas and liquid inside.

NOTICE:
- As gas may spray out, cover the brake booster accumulator with a cloth when performing the operation.
- Work slowly and do not cut the hole too quickly or suddenly.
- Wear protective glasses during the operation.

c. When the outer body of the brake booster accumulator is cut, gas and liquid discharge.

HINT:
- The gas is colorless, odorless and nonpoisonous nitrogen gas.
- The liquid is brake fluid.





26. INSTALL BRAKE BOOSTER ACCUMULATOR ASSEMBLY
a. Place the brake booster pump in a vise with a cloth.
b. Install the brake booster accumulator pipe, compression spring and a new O-ring.

NOTICE: Ensure that no foreign matter enters the pump.

c. Using a socket wrench (17 mm), install the brake booster accumulator onto the brake booster pump.
Torque: 57.4 Nm (585 kgf-cm, 42 ft. lbs.)





27. INSTALL MASTER CYLINDER SOLENOID
a. Place a new gasket on the master cylinder solenoid and install them onto the master cylinder body with 6 new bolts.
Torque: 31.9 Nm (325 kgf-cm, 24 ft. lbs.)

NOTICE: Do not let water, dust, and/or other objects attach to the surface and/or attaching surface of the master cylinder solenoid, master cylinder and body gasket.

28. INSTALL PISTON
a. Apply lithium soap base glycol grease to the new piston.
b. Install the piston onto the master cylinder body.





c. Using 2 screwdrivers, install a new C-ring while pressing the piston

NOTICE:
- If the piston is pulled out at an angle, there is a possibility that the cylinder bore could be damaged.
- Be careful not to damage the rubber lips on the piston when reassembling.

29. INSTALL MASTER CYLINDER BOOT
30. INSTALL MASTER CYLINDER PUSH ROD CLEVIS
a. Install the lock nut and master cylinder push rod clevis onto the rod operating adapter.
b. Install the brake master cylinder side lock nut and rod operating adapter onto the brake master cylinder.
Torque: 25.5 Nm (260 kgf-cm, 19 ft. lbs.)





31. INSTALL BRAKE BOOSTER PUMP BRACKET
a. Using a hexagon wrench (5 mm), install the brake booster pump bracket with the 2 screws.
Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.)
b. Install the bush onto the brake booster pump bracket.





32. INSTALL BRAKE ACTUATOR BRACKET
a. Using a hexagon wrench (5 mm), install the brake actuator bracket with the screw.
Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.)





33. INSTALL BRAKE BOOSTER W/ACCUMULATOR PUMP ASSEMBLY
a. Install the 2 collars and 2 bushes onto the brake booster w/ accumulator pump assembly.
b. Using a hexagon wrench (4 mm), install the 2 pins.
Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.)





c. Install the brake booster w/ accumulator pump assembly.





d. Install a new clip.





e. Install the wire harness with the 2 screws.
Torque: 2.9 Nm (30 kgf-cm, 26 inch lbs.)





f. Install the 2 new plugs.





34. INSTALL BRAKE ACTUATOR TUBE NO.1
a. Using SST, install the brake actuator tube No.1.
SST 09023-00101
Torque:
15.2 Nm (155 kgf-cm, 11 ft. lbs.) for use without SST
14 Nm (143 kgf-cm, 10 ft. lbs.) for use with SST

HINT:
- Use a torque wrench with a fulcrum length of 250 mm (9 84 inch)
- This torque value is effective when SST is parallel to a torque wrench.





35. INSTALL BRAKE ACTUATOR HOSE
a. Using needle-nose pliers, install the brake actuator hose and 2 clips.
36. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY
a. Install the cap.
b. Apply lithium soap base glycol grease to the 3 new grommets.
c. Install the 3 grommets to the master cylinder body.

NOTICE: Be careful of the size of each grommets.

d. Install the master cylinder reservoir.





e. Using a pin punch and hammer, install a new pin onto the master cylinder reservoir.





f. Install the screw onto the master cylinder reservoir.
Torque: 1.7 Nm (17 kgf-cm, 15 inch lbs.)





37. INSTALL BRAKE ACTUATOR BRACKET NO.1
a. Install the fluid level warning switch connector.
b. Using a hexagon wrench (5 mm), install the brake actuator bracket No.1 with the screw.
Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.)





38. INSTALL BRAKE MASTER CYLINDER ASSEMBLY
a. Install a new brake booster gasket onto the master cylinder.
b. Install the brake master cylinder with the 4 nuts.
Torque: 14.2 Nm (145 kgf-cm, 10 ft. lbs.)





c. Using SST, connect the 4 brake lines to the correct positions of the brake master cylinder, as shown in the illustration. SST 09023-00101
Torque: 15.2 Nm (155 kgf-cm, 11 ft. lbs.)





d. Connect the 3 connectors.
39. INSTALL MASTER CYLINDER PUSH ROD CLEVIS
40. INSTALL DRIVER SIDE JUNCTION BLOCK
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
41. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER NO.1
42. INSTALL INSTRUMENT PANEL UNDER TRAY (AUTOMATIC TRANSAXLE)
43. INSTALL INSTRUMENT PANEL HOLE COVER (MANUAL TRANSAXLE)
44. INSTALL COWL SIDE TRIM BOARD LH
45. INSTALL FRONT DOOR SCUFF PLATE LH
46. INSTALL FRONT FLOOR FOOTREST
47. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.)
48. CHECK BRAKE PEDAL HEIGHT
49. CHECK PEDAL FREE PLAY
50. CHECK PEDAL RESERVE DISTANCE
51. FILL RESERVOIR WITH BRAKE FLUID
52. BLEED BRAKE BOOSTER W/ ACCUMULATOR PUMP ASSEMBLY
53. BLEED BRAKE LINE
54. BLEED MASTER CYLINDER SOLENOID
55. CHECK FLUID LEVEL IN RESERVOIR
56. CHECK FOR BRAKE FLUID LEAKAGE
57. CHECK BRAKE MASTER CYLINDER OPERATION