Removal and Replacement

BRAKE MASTER CYLINDER

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

REMOVAL
1. DRAIN BRAKE FLUID

NOTICE: Immediately wash off any brake fluid that comes into contact with any painted surfaces.

2. REMOVE BATTERY
3. REMOVE BATTERY TRAY
4. REMOVE BATTERY CARRIER

5. DISCONNECT CLUTCH RESERVOIR TUBE (for Manual Transaxle)
(a) Slide the clip and disconnect the reservoir tube.

6. REMOVE BRAKE MASTER CYLINDER

NOTICE: Remove the brake master cylinder after depressing the brake pedal several times and bleeding the vacuum pressure from inside the brake booster.

(a) Disconnect the brake fluid level warning switch connector.

(b) w/o ABS:
(1) Using SST, separate the 3 brake tubes from the brake tube way.
SST 09023-00100

(d) w/ ABS:
(1) Remove the 2 nuts and remove the brake master cylinder.

(e) w/o ABS:
(1) Remove the 2 nuts and brake tube way and remove the brake master cylinder.
(f) Remove the O-ring from the brake master cylinder.

INSTALLATION

1. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD
(a) Set SST on the master cylinder and lower the rod of SST until it just touches the piston.
SST 09737-00013
(b) Apply chalk to the flat tip of the SST rod. Turn SST upside down and measure the clearance between the brake booster push rod and SST.
Standard Clearance: -0.21 to 0 mm (-0.0083 to 0 in.)

If there is clearance between the SST main body and the shell of the brake booster, the push rod is protruding too far. If the chalk does not stick to the tip of the brake booster push rod, the push rod protrusion is insufficient.

(c) If the clearance is not within the standard, adjust the length by holding the rod using SST and turning the tip of the rod using a 7 mm socket driver.
SST 09737-00020

NOTICE: Check the push rod clearance again after adjusting.

2. INSTALL BRAKE MASTER CYLINDER
(a) Install a new O-ring onto the brake master cylinder.

(b) w/ ABS:
(1) Install the brake master cylinder with the 2 nuts.
Torque: 13 N*m (127 kgf*cm, 9 ft.*lbf)

(c) w/o ABS:
(1) Install the brake master cylinder and brake tube way with the 2 nuts.
Torque: 13 N*m (127 kgf*cm, 9 ft.*lbf)

(d) Using SST, install the 2 brake tubes onto the brake master cylinder.
SST 09023-00100
Torque: for use without SST
15 N*m (155 kgf*cm, 11 ft.*lbf)
for use with SST
14 N*m (143 kgf*cm, 10 ft.*lbf)

HINT:
^ Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).
^ This torque value is effective when SST is parallel to a torque wrench.

(e) w/o ABS:
(1) Using SST, install the 3 brake tubes to the brake tube way.
SST 09023-00100
Torque: for use without SST
15 N*m (155 kgf*cm, 11 ft.*lbf) for use with SST
14 N*m (143 kgf*cm, 10 ft.*lbf)

HINT:
^ Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).
^ This torque value is effective when SST is parallel to a torque wrench.

(f) Connect the brake fluid level warning switch connector.

3. CONNECT CLUTCH RESERVOIR TUBE (for Manual Transaxle)
(a) Connect the reservoir tube with the clip.

4. INSTALL BATTERY CARRIER
5. INSTALL BATTERY TRAY
6. INSTALL BATTERY
7. FILL RESERVOIR WITH BRAKE FLUID
8. BLEED MASTER CYLINDER
9. BLEED BRAKE LINE
10. CHECK FLUID LEVEL IN RESERVOIR
11. CHECK FOR BRAKE FLUID LEAKAGE