Page 2753 of 3833

BRAKE MASTER CYLINDER
BR-13
C
D
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B
BR
BRAKE MASTER CYLINDERPFP:46010
ComponentsEFS000CB
Removal and InstallationEFS001CG
REMOVAL
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. Drain brake fluid.
2. Remove fluid level sensor harness connector.
3. Using a flare nut wrench, disconnect master cylinder assembly and brake tube.
4. First remove master cylinder assembly mounting nuts. Then remove master cylinder assembly.
INSTALLATION
1. Connect brake tube to master cylinder assembly and temporarily tighten flare nut by hand.
2. Connect master cylinder assembly to brake booster assembly and tighten mounting nuts to the specified
torque.
3. Tighten brake tube flare nuts.
4. Connect fluid level sensor harness connector.
5. Refill with new brake fluid and bleed air from the brake piping.
1. Cap 2. Strainer 3. Reservoir tank
4. Grommet 5. Piston stopper 6. Pin
7. Secondary piston 8. Primary piston assembly 9. Stopper cap
SFIA0047E
: 15 - 17 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
Page 2754 of 3833

BR-14
BRAKE MASTER CYLINDER
Disassembly and Assembly
EFS001CH
DISASSEMBLY
CAUTION:
Remove master cylinder reservoir tank only when necessary.
1. Using a slotted screwdriver as shown in the figure, lever stopper
cap tabs up and remove stopper cap. While removing, be sure
to hold cap securely to prevent the master cylinder piston from
popping out.
2. Secure cylinder body flange in a vise as shown in the figure.
CAUTION:
●Secure with chamfered pin insert hole on the cylinder
body facing upward.
●When securing in the vise, use copper plates or cloth to
protect the flange.
3. Using a pin punch [tool: diameter Approx. 4 mm (0.16 in)],
remove reservoir tank mounting pins.
4. Remove master cylinder assembly from the vise.
5. Remove reservoir tank and grommet from the cylinder body.
6. Using a Phillips screwdriver, press and hold piston pin as shown
in the figure. Remove piston stopper from the cylinder body.
7. Carefully pull primary piston assembly straight out to prevent
damage to the cylinder inner wall.
8. Tap flange against a wood block to loosen secondary piston
assembly. Carefully pull secondary piston assembly straight out
to prevent damage to the cylinder inner wall.
INSPECTION AFTER REMOVAL
●Check cylinder inner wall for damage, wear, corrosion, and pinholes. Replace cylinder if damage, wear, or
corrosion is detected.
BRA0533D
BRA0588D
SFIA0342E
BRA0590D
Page 2755 of 3833

BRAKE MASTER CYLINDER
BR-15
C
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BR
ASSEMBLY
CAUTION:
●Never use mineral oils such as kerosene or gasoline during the cleaning and assembly processes.
●Be sure there is no foreign material on the cylinder inner wall, piston, and cup seal. Be careful not
to damage parts with a service tool during assembly.
●Do not drop the parts. Do not use any dropped parts.
1. Apply brake fluid to the inner wall of cylinder body and contact
surface of the piston assembly. Then insert secondary piston
assembly and primary piston assembly into cylinder body in this
order.
CAUTION:
●Do not reuse primary and secondary piston assemblies.
●Always replace the inner kit as an assembly.
●Pay attention to orientation of the piston cup. Insert it
straight in order to prevent it from catching on the cylin-
der's inner wall.
2. Visually check secondary piston slit position through cylinder
body secondary tank boss hole and install piston stopper.
3. Hold piston with stopper cap. Press stopper cap in until its tabs
fully engage groove on the cylinder body.
CAUTION:
Do not reuse stopper cap.
4. Apply brake fluid to grommet before pressing it into cylinder
body.
CAUTION:
Do not reuse grommet.
5. Secure cylinder body flange in a vise as shown in the figure.
CAUTION:
●Secure with chamfered pin insert hole on the cylinder body
facing upward.
● When securing in the vise, use copper plates or cloth to
protect the flange.
6. Install reservoir tank to the cylinder body. Tilt reservoir tank as
shown in the figure and insert mounting pin. When mounting pin
passes through pinhole in the master cylinder, return reservoir
tank to the upright position. Push mounting pin all the way
through the opposite pinhole in the reservoir tank.
CAUTION:
●Do not reuse reservoir tank mounting pin.
SFIA0248E
BRA0590D
BRA0535D
SFIA0343E
Page 2756 of 3833
BR-16
BRAKE MASTER CYLINDER
●Do not reuse reservoir tank.
●Be sure to insert pin from the chamfered pinhole on the cylinder body.
Page 2757 of 3833

BRAKE BOOSTER
BR-17
C
D
E
G
H
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MA
B
BR
BRAKE BOOSTERPFP:47200
On-Vehicle Inspection and ServiceEFS000CC
FUNCTION INSPECTION
With the engine stopped, discharge stored vacuum by depressing
brake pedal several times at 5 second intervals. With the brake
pedal fully depressed, start the engine. Confirm that clearance
between brake pedal and the floor panel decreases when engine
vacuum stabilizes.
AIRTIGHTNESS INSPECTION
●Run the engine at idle for approximately 1 minute. Stop it after
applying vacuum to the booster. Depress the brake pedal sev-
eral times with normal force to discharge the stored vacuum.
Confirm that clearance between brake pedal and the floor panel
gradually increases as the brake pedal is depressed.
●Run the engine. Depress and hold the brake pedal then stop the
engine. Keep the brake pedal depressed for 30 seconds or more
and make sure the pedal stroke does not change.
Removal and InstallationEFS000CD
REMOVAL
CAUTION:
●Be careful not to deform or bend brake piping while removing and installing the brake booster.
●Replace clevis pin if it is damaged.
●Be careful not to damage brake booster stud bolt threads. If brake booster is tilted or inclined dur-
ing installation, the dash panel may damage the threads.
●Be sure to install the check valve in the correct orientation.
1. Remove vacuum piping from the brake booster.
2. Remove master cylinder.
3. Remove snap pin and clevis pin on passenger compartment clevis. Remove input rod from the brake
pedal.
4. Remove brake booster and brake pedal assembly mounting nuts.
5. Remove booster assembly from the engine compartment.
BRA0037D
SBR365AA
SFIA0139E
Page 2758 of 3833
BR-18
BRAKE BOOSTER
INSPECTION AFTER REMOVAL
Output rod length inspection
1. Using a handy vacuum pump, apply a vacuum of -66.7 kPa (-500 mmHg, -19.69 inHg) to the brake
booster.
2. Check output rod length.
3.
INSTALLATION
1. Loosen lock nut to adjust input rod length so that length “B” (in
the figure) satisfies the specified value.
2. After adjusting B, temporarily tighten lock nut to install booster
assembly to vehicle.
3. Connect brake pedal to input rod clevis.
4. Connect brake pedal assembly mounting nuts and tighten to the
specified torque.
5. Connect master cylinder to the booster assembly.
6. Adjust brake pedal height and play.
7. Tighten input rod lock nut to the specified torque.
8. Bleed air. Refer to BR-10, "
Bleeding Brake System" . Reference value at vacuum of -66.7 kPa (-500 mmHg, -
19.69 inHg):
10.4 mm (0.409 in)
SBR208E
Length “B” standard : 125 mm (4.92 in)
SGIA0060E
Page 2759 of 3833
VACUUM LINES
BR-19
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B
BR
VACUUM LINESPFP:41920
Removal and InstallationEFS000CE
CAUTION:
●Because vacuum hose contains a check valve, it must be installed in the correct orientation. Refer
to the stamp or label to confirm correct installation. The brake booster will not operate normally if
the hose is installed in the wrong direction.
●Insert the vacuum hose for at least 24 mm (0.94 in).
●Never use lubricating oil during assembly.
InspectionEFS000CF
VISUAL INSPECTION
Check for improper assembly, damage and aging.
1. Vacuum hose 2. Vacuum tube 3. Clip
4. Clamp
SFIA0369E
SBR225B
Page 2760 of 3833
BR-20
VACUUM LINES
CHECK VALVE INSPECTION
Airtightness Inspection
Use a hand-held vacuum pump to check.
When connected to booster side (1):
Vacuum decrease should be within 1.3 kPa
(10 mmHg, 0.39 inHg) for 15 seconds under
a vacuum of -66.7 kPa (-500 mmHg, -19.69
inHg)
When connected to engine side (2):
No vacuum will be applied
SFIA0210E