Page 3009 of 4555
BRAKE PIPING AND HOSE
BR-11
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LHD MODELS
Removal and Installation of Front Brake Piping and Brake HoseEFS000C7
REMOVAL
CAUTION:
Do not allow brake fluid to spill or splash on painted surfaces. Brake fluid can seriously damage
paint. If it gets on a painted surface, wipe it off immediately and wash it away with water.
Do not bend or twist brake hose sharply, or strongly pull it.
Cover brake fluid line joints to prevent dust and other foreign material.
1. Connect a vinyl tube to bleed valve.
2. Drain brake fluid gradually from bleed valve of each wheel while depressing brake pedal.
SFIA2137E
SFIA2138E
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BR-12
BRAKE PIPING AND HOSE
3. Using a flare nut wrench, loosen brake tube flare nuts and dis-
connect brake tube from brake hose.
4. Remove union bolts and disconnect caliper assembly from
brake hose.
5. First remove lock spring from brake tube and strut mounting
positions. Then remove brake hose.
INSTALLATION
CAUTION:
Refill with new brake fluid “DOT 3” or “DOT4”.
Never reuse drained brake fluid.
1. Connect brake hose to caliper assembly and tighten union bolt to the specified torque.
CAUTION:
Securely connect brake hose to the protrusion on the cylinder body.
Do not reuse the copper washer for union bolt.
2. Connect brake hose to strut and fix with lock spring.
3. Connect brake hose to brake tube. Temporarily tighten flare nuts by hand as far as they will go. Secure
them with the lock spring.
4. Using a flare nut torque wrench, tighten to the specified torque.
5. Refill brake fluid until new brake fluid comes out of each bleed valve.
6. Afterwards, bleed air.
Removal and Installation of Rear Brake Piping and Brake HoseEFS000C8
REMOVAL
CAUTION:
Do not allow brake fluid to spill or splash on painted surfaces. Brake fluid can seriously damage
paint. If it gets on a painted surface, wipe it off immediately and wash it away with water.
Do not bend or twist brake hose sharply, or strongly pull it.
Cover brake fluid line joints to prevent dust and other foreign material.
1. Connect a vinyl tube to bleed valve.
2. Drain brake fluid gradually from bleed valve of each wheel while depressing brake pedal.
3. Using a flare nut wrench, remove brake tube flare nuts and dis-
connect brake tube from brake hose.
4. Remove lock spring.
INSTALLATION
CAUTION:
Refill with new brake fluid “DOT 3” or “DOT 4”.
Never reuse drained brake fluid.
1. Connect brake hose to the brake tube. Temporarily tighten flare nut by hand as far as it will go.
2. Fix brake hose by lock plate.
SFIA0347E
: 15 - 17 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
SFIA0046E
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BRAKE PIPING AND HOSE
BR-13
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3. Tighten flare nut by using a flare nut wrench with the specified
torque.
4. Refill brake fluid until new brake fluid comes out of each bleed
valve.
5. Afterwards, bleed air.
InspectionEFS000C9
CAUTION:
If any leaks on joints, retighten it. Replace any damaged parts.
1. Check hose, tube, and joints for fluid leaks, damage, twist, deformation, contact with other parts, and
loose connections.
2. Run engine. Depress brake pedal and hold it for approximately 5 seconds while checking each part for
leaks.: 15 - 17 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
SBR820BA
Page 3012 of 4555

BR-14
BRAKE MASTER CYLINDER
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, wipe it off immediately and wash it away with water.
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.
1. Reservoir tank 2. Reservoir cap 3. Oil strainer
4. Pin 5. Cylinder body 6. Piston stopper (Some models with
ABS does not apply.)
7. Grommet 8. O-ring 9. Secondary piston assembly
10. Primary piston assembly 11. Snap ring 12. Guide assembly
13. Plate 14. Stopper cap 15. Primary piston assembly
16. Secondary piston assembly
SFIA1800E
: 15 - 17 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
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BRAKE MASTER CYLINDER
BR-15
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5. Refill with new brake fluid and bleed air from the brake piping.
Disassembly and AssemblyEFS001CH
MODELS WITHOUT ESP (PISTON STOPPER APPLIED.)
Disassembly
CAUTION:
Remove master cylinder reservoir tank only when necessary.
1. Using a slotted flat-bladed screwdriver as shown in the figure,
lever up stopper cap tabs 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 cylinder body flange with chamfered pin insert
hole, 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 flat-bladed screwdriver, press and hold piston
pin as shown in the figure. Remove piston stopper from the cyl-
inder 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 Disassembly
Check cylinder inner wall for damage, wear, corrosion, and pinholes. Replace cylinder if damage, wear, or
corrosion is detected.
BRA0533D
BRA0588D
SFIA0342E
BRA0590D
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BR-16
BRAKE MASTER CYLINDER
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 piston assembly. Then insert secondary piston
assembly and primary piston assembly into the cylinder body in
this order.
CAUTION:
Do not reuse primary and secondary piston assemblies.
Always replace primary and secondary piston assemblies
as kit.
Pay attention to orientation of the piston cup. Insert it
straight in order to prevent the cups from catching between
the cylinder's inner wall and piston.
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 cylinder body flange with chamfered pin insert hole
facing upward.
When securing in the vise, use copper plates or cloth to
protect the flange.
6. Install reservoir tank to cylinder body. Tilt reservoir tank as
shown in the figure to the extent that the mounting pin can be
inserted and insert mounting pin. When mounting pin passes
through pinhole in master cylinder, return reservoir tank to the
upright position. Push mounting pin all the way through the
opposite pinhole in the reservoir tank.
SFIA0248E
BRA0590D
BRA0535D
SFIA0343E
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BRAKE MASTER CYLINDER
BR-17
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CAUTION:
Do not reuse reservoir tank mounting pin.
Do not reuse reservoir tank.
Be sure to insert pin from the chamfered pinhole on the cylinder body.
MODELS WITHOUT ESP (PISTON STOPPER NOT APPLIED.)
CAUTION:
Remove reservoir tank only when absolutely necessary.
Disassembly (Piston Assembly)
1. Using a flat-bladed screwdriver as shown in the figure, lift up the
tabs on the stopper cap and remove it from the master cylinder.
NOTE:
Remove stopper cap while holding it because the piston in mas-
ter cylinder may pop out.
2. Carefully pull primary piston assembly straight out to prevent the
cylinder inner wall from being damaged.
3. Tap flange using a soft block, such as wood, and carefully pull
secondary piston assembly straight out to prevent cylinder body
inner wall from being damaged.
Inspection After Disassembly (Piston Assembly)
Cylinder body
Check inner wall of cylinder for damage, abrasion, corrosion, and pinholes. Replace the cylinder body if
detected.
Assembly (Piston Assembly)
CAUTION:
Do not use mineral oils such as kerosene, gasoline during the cleaning and assembly process.
Make sure there is no foreign matter such as dirt or dust attached to the inner cylinder walls, the
piston, or the cap seal, and use care to avoid damaging parts with the assembly tools.
Do not drop parts. If a part is dropped, do not use it.
1. Apply fluid to cylinder inner wall body and contact surface of the
piston assembly. Then insert secondary piston assembly and
primary piston assembly into cylinder body in this order.
CAUTION:
Pay attention to the orientation of the piston cup, and
insert straight to prevent the cup from being caught by
cylinder inner wall.
Be sure to replace the assembly without disassembling
the new inner kit.
Do not reuse the primary and secondary piston assem-
blies.
BRA0031D
BRA0033D
SFIA2051E
Page 3016 of 4555

BR-18
BRAKE MASTER CYLINDER
2. Holding down the piston with the stopper cap, push the stopper
cap tabs so they are firmly into the cylinder grooves, then attach
the stopper cap.
CAUTION:
Do not reuse the stopper cap.
Disassembly (Reservoir Tank)
1. Secure master cylinder assembly into a vise with the chamfered
pin insert hole on cylinder body facing upward.
CAUTION:
When setting the master cylinder assembly in a vise, be
sure not to over-tighten.
When securing in a vise use copper plates or cloth to
protect the flange.
2. Using a pin punch [commercial service tool: diameter approxi-
mately 4 mm (0.16 in)], remove mounting pins on the reservoir
tank.
3. Remove master cylinder assembly from the vise.
4. Remove reservoir tank and grommet from cylinder body.
Assembly (Reservoir Tank)
1. Apply brake fluid or rubber lubricant to a grommet, and then install it into cylinder body after installing
grommet to reservoir tank.
CAUTION:
Do not reuse the reservoir tank and grommet.
2. Secure master cylinder assembly into a vise with the chamfered
pin insert hole on cylinder body facing upward.
CAUTION:
When setting the master cylinder assembly in a vise, be
sure not to over-tighten.
When securing in a vise use copper plates or cloth to
protect the flange.
BRA0035D
BRA0588D
SFIA0342E
BRA0588D