Page 137 of 2267
Removal
1. Reservoir cap
2. Oil filter
3. Reservoir tank
4. Seal5. Cylinder body
6. Elastic pin
7. Piston stopper pin8. Secondary piston assembly
9. Primary piston assembly
10. Circlip
CAUTION:
Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted
areas, wash it away with water immediately.
1. Disconnect fluid level connector.
2. Connect a vinyl tube to air bleeder valve.
3. Drain brake fluid from each air bleeder valve, depressing
brake pedal to empty fluid from master cylinder.
4. Remove brake pipe flare nuts.
5. Remove master cylinder mounting nuts.
Disassembly
1. Drive out elastic pin from cylinder body.
2. Remove reservoir tank and seals.
NBR436
SBR231E
MASTER CYLINDER
BR-15
Page 138 of 2267

3. Remove the circlip with suitable pliers while piston is pushed
into cylinder.
4. Remove piston stopper pin while piston is pushed into cylin-
der.
5. Remove piston assemblies.
If it is difficult to remove secondary piston assembly,
gradually apply compressed air through fluid outlet.
Inspection
Check for the following items.
Replace any part if damaged.
Master cylinder:
lPin holes or scratches on inner wall.
Piston:
lDeformation of or scratches on piston cups.
Assembly
1. Insert secondary piston assembly. Then insert primary piston
assembly.
lPay attention to alignment of secondary piston slit with
valve stopper mounting hole of cylinder body.
2. Install piston stopper pin while piston is pushed into cylinder.
Then secure the primary and secondary piston assemblies
with new circlip.
3. Push reservoir tank seals and reservoir tank into cylinder
body.
4. Install elastic pin.
NBR353
Push
Piston stop-
per pin
SBR232E
Secondary piston
Primary piston
SBR233E
Push
Piston stop-
per pin
SBR232E
MASTER CYLINDER
Disassembly (Cont'd)
BR-16
Page 139 of 2267
Installation
CAUTION:
lRefill with new brake fluid ªDOT 4º.
lNever reuse drained brake fluid.
1. Place master cylinder onto brake booster and secure mount-
ing nuts lightly.
2. Torque mounting nuts.
: 14 - 17 N´m (1.5 - 1.7 kg-m, 11 - 12 ft-lb)
3. Fill up reservoir tank with new brake fluid.
4. Plug all ports on master cylinder with fingers to prevent air
suction while releasing brake pedal.
5. Have driver depress brake pedal slowly several times until no
air comes out of master cylinder.
6. Fit brake lines to master cylinder.
7. Tighten flare nuts.
: 15 - 18 N´m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
8. Connect fluid level connector.
9. Bleed air from brake system. Refer to ªBleeding Brake
Systemº, BR-8.
SBR236E
MASTER CYLINDER
BR-17
Page 140 of 2267
On-vehicle Service
OPERATING CHECK
1. Depress brake pedal several times with engine off. After
exhausting vacuum, make sure there is no change in pedal
stroke.
2. Depress brake pedal, then start engine. If pedal goes down
slightly, operation is normal.
AIRTIGHT CHECK
1. Start engine, and stop it after one or two minutes. Depress
brake pedal several times slowly. Booster is airtight if pedal
stroke is less each time.
2. Depress brake pedal while engine is running, and stop
engine with pedal depressed. The pedal stroke should not
change after holding pedal down for30 seconds.
Removal
CAUTION:
lBe careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
lBe careful not to deform or bend brake pipes, during
removal of booster.
SBR002A
SBR365AA OK NG
Third
Second
First
NBR437
BRAKE BOOSTER
BR-18
Page 141 of 2267

Inspection
OUTPUT ROD LENGTH CHECK
1. Supply brake booster with vacuum of þ66.7 kPa (þ667 mbar,
þ500 mmHg, þ19.69 inHg) using a hand vacuum pump.
2. Add preload of 19.6N (2.0 kg, 4.4lb) to output rod.
3. Check output rod length.
Specified length:
10.275 - 10.525 mm (0.4045 - 0.4144 in)
Installation
CAUTION:
lBe careful not to deform or bend brake pipes during
installation of booster.
lReplace clevis pin if damaged.
lRefill with new brake fluid ªDOT 4º.
lNever reuse drained brake fluid.
lTake care not to damage brake booster mounting bolt
thread when installing. Due to the acute angle of
installation, the threads can be damaged on the metal
surrounding the dash panel holes.
1. Before fitting booster, temporarily adjust clevis to dimension
shown in the table.
Adjustment mm (in)
LHD 127.5 (5.02)
RHD 125 (4.92)
2. Fit booster, then secure mounting nuts (brake pedal bracket
to booster) lightly.
3. Connect brake pedal and booster input rod with clevis pin.
4. Secure mounting nuts.
Specification:
: 11 - 17 N´m (1.2 - 1.7 kg-m,9-12ft-lb)
5. Install master cylinder. Refer to BR-14.
6. Bleed air. Refer to ªBleeding Brake Systemº, BR-8.
7. Adjust pedal height to specification. Refer to SDS (BR-92).
Retighten clevis locknut.
Specification:
: 16 - 22 N´m (1.6 - 2.2 kg-m, 12 - 16 ft-lb)
SBR281A Output rod length
Approx. 125 - 127.5 (4.92 - 5.02)
Clevis Clevis lock-
nut
mm (in)
NBR191
BRAKE BOOSTER
BR-19
Page 142 of 2267
NBR421
Diesel models
Tube
Check valve
To Intake manifold
Check valveCheck valve
Vacuum reservoirLHD Petrol models
RHD Petrol models
To Brake booster Vacuum hose To intake
manifold
.Vacuum hose To brake booster
VACUUM HOSE
BR-20
Page 143 of 2267
Removal and Installation
CAUTION:
When installing vacuum hoses, pay attention to the follow-
ing points.
lDo not apply any oil or lubricants to vacuum hose and
check valve.
lInsert vacuum tube into vacuum hose as shown.
lInstall check valve, paying attention to its direction.
Inspection
HOSES AND CONNECTORS
Check vacuum lines, connections and check valve for air
tightness, improper attachment, chafing and deterioration.
CHECK VALVE
Check vacuum with a vacuum pump.
Connect to
booster sideVacuum should exist.
Connect to
engine sideVacuum should not exist.
SBR225B More than 24 mm
(0.94 in)
Connect hose until it contacts pro-
trusion on vacuum tube.
SBR498A Intake manifold
sideBrake booster
side
NBR385 CAUTION
Caution label
ENG.
SBR943A Booster side
Engine side
VACUUM HOSE
BR-21
Page 144 of 2267
VACUUM PUMP
1. Install vacuum gauge.
2. Run engine at 1,000 rpm or more.
3. Check vacuum.
Specified vacuum:
86.6 kPa (866 mbar, 650 mmHg, 25.59 inHg) or
more
Booster side
Engine side
Arrow indicates
engine side
SBR844B
SBR209DA Vacuum gauge
VACUUM HOSE
Inspection (Cont'd)
BR-22