Page 1577 of 2000

BR–24BRAKE – BRAKE MASTER CYLINDER
BR
REMOVAL
(2006/01- )
NOTICE:
• The master cylinder and piston are designed so that
the piston can easily fall out. Prevent this by making
sure that the tip of the master cylinder points
downward when handling the master cylinder.
• Make sure foreign matter does not attach to the
master cylinder's piston. If foreign matter attaches,
clean it off with a cloth. Then apply lithium soap base
glycol grease to the entire outer circumference
contact surface area of the piston.
1. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (for
2AZ-FE)
(a) Remove the air cleaner case (see page EM-98).
HINT:
Refer to the procedures from the removal of the
purge VSV up until the removal of the air cleaner
case.
2. REMOVE AIR CLEANER CASE (for 2GR-FE)
(a) Remove the air cleaner case (see page EM-21).
HINT:
Refer to the procedures from the removal of the air
cleaner cap sub-assembly up until the removal of
the air cleaner case.
3. DRAIN BRAKE FLUID
NOTICE:
Wash off brake fluid immediately if it comes in
contact with any painted surface.
4. REMOVE BRAKE MASTER CYLINDER SUB-
ASSEMBLY
(a) Release the vacuum pressure in the brake booster
as follows.
(1) Stop the engine.
(2) Depress the brake pedal several times.
(b) Disconnect the brake fluid level warning switch
connector labeled A.
(c) Using SST, disconnect the 2 brake lines labeled B
from the master cylinder.
SST 09023-00101
C127053E01
Page 1578 of 2000
BRAKE – BRAKE MASTER CYLINDERBR–25
BR
(d) Remove the 2 nuts.
(e) Pull out the master cylinder from the brake booster.
NOTICE:
• The master cylinder and piston are designed
so that the piston can easily fall out. Prevent
this by making sure that the tip of the master
cylinder points downward when handling the
master cylinder.
• Make sure foreign matter does not attach to
the master cylinder's piston. If foreign matter
attaches, clean it off with a cloth. Then apply
lithium soap base glycol grease to the entire
outer circumference contact surface area of
the piston.
(f) Remove the O-ring from the master cylinder.
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Page 1579 of 2000
BR–26BRAKE – BRAKE MASTER CYLINDER
BR
DISASSEMBLY
NOTICE:
• The master cylinder and piston are designed so that
the piston can easily fall out. Prevent this by making
sure to tip of the master cylinder points downward
when handling the master cylinder.
• Make sure foreign matter does not attach to the
master cylinder's piston. If foreign matter attaches,
clean it off with a cloth. Then apply lithium soap base
glycol grease to the entire outer circumference
contact surface area of the piston.
1. REMOVE BRAKE MASTER CYLINDER RING PIN
2. REMOVE BRAKE MASTER CYLINDER RESERVOIR
SUB-ASSEMBLY
3. REMOVE MASTER CYLINDER RESERVOIR
GROMMET
4. REMOVE BRAKE MASTER CYLINDER RESERVOIR
FILLER CAP ASSEMBLY
5. REMOVE BRAKE MASTER CYLINDER RESERVOIR
STRAINER
Page 1580 of 2000

BRAKE – BRAKE MASTER CYLINDERBR–27
BR
INSPECTION
NOTICE:
• The master cylinder and piston are designed so that
the piston can easily fall out. Prevent this by making
sure that the tip of the master cylinder points
downward when handling the master cylinder.
• Make sure foreign matter does not attach to the
master cylinder's piston. If foreign matter attaches,
clean it off with a cloth. Then apply lithium soap base
glycol grease to the entire outer circumference
contact surface area of the piston.
1. INSPECT AND ADJUST BRAKE BOOSTER PUSH
ROD
HINT:
Adjust the booster push rod when the master cylinder is
replaced with a new one. Adjustment is not necessary
when the master cylinder is reinstalled and the booster is
replaced with a new one.
(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.
G028332E02
C128539E01
Page 1581 of 2000
BR–28BRAKE – BRAKE MASTER CYLINDER
BR
REASSEMBLY
NOTICE:
• The master cylinder and piston are designed so that
the piston can easily fall out. Prevent this by making
sure to tip of the master cylinder points downward
when handling the master cylinder.
• Make sure foreign matter does not attach to the
master cylinder's piston. If foreign matter attaches,
clean it off with a cloth. Then apply lithium soap base
glycol grease to the entire outer circumference
contact surface area of the piston.
1. INSTALL BRAKE MASTER CYLINDER RESERVOIR
STRAINER
2. INSTALL BRAKE MASTER CYLINDER RESERVOIR
FILLER CAP ASSEMBLY
3. INSTALL MASTER CYLINDER RESERVOIR
GROMMET
(a) Apply lithium soap base glycol grease to 2 new
grommets, and then install them to the master
cylinder.
4. INSTALL BRAKE MASTER CYLINDER RESERVOIR
SUB-ASSEMBLY
5. INSTALL BRAKE MASTER CYLINDER RING PIN
C128540E01
Page 1582 of 2000

BRAKE – BRAKE MASTER CYLINDERBR–29
BR
INSTALLATION
(2005/11-2006/01)
1. INSTALL BRAKE MASTER CYLINDER SUB-
ASSEMBLY
NOTICE:
• The master cylinder and piston are designed so
that the piston can easily fall out. Prevent this by
making sure that the tip of the master cylinder
points downward when handling the master
cylinder.
• Make sure foreign matter does not attach to the
master cylinder's piston. If foreign matter
attaches, clean it off with a cloth. Then apply
lithium soap base glycol grease to the entire outer
circumference contact surface area of the piston.
(a) Install a new O-ring to the master cylinder.
(b) Install the master cylinder to the booster with the 2
nuts.
Torque: 12.5 N*m (127 kgf*cm, 9 ft.*lbf)
(c) Using SST, connect the 2 brake lines labeled B to
the master cylinder.
SST 09023-00101
Torque: 15.2 N*m (155 kgf*cm, 11 ft.*lbf) without
SST
14 N*m (144 kgf*cm, 10 ft.*lbf) with SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.).
(d) Connect the brake fluid level warning switch
connector labeled A to the master cylinder.
2. FILL RESERVOIR WITH BRAKE FLUID (See page BR-
6)
3. BLEED AIR FROM BRAKE MASTER CYLINDER (See
page BR-7)
4. BLEED AIR FROM BRAKE LINE (See page BR-7)
5. BLEED AIR FROM ABS AND TRACTION ACTUATOR
ASSEMBLY (See page BR-8)
6. CHECK BRAKE FLUID LEVEL IN RESERVOIR (See
page BR-6)
7. CHECK FOR BRAKE FLUID LEAKAGE
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Page 1583 of 2000
BR–30BRAKE – BRAKE MASTER CYLINDER
BR
8. INSTALL AIR CLEANER CASE SUB-ASSEMBLY
(a) Install the air cleaner case (see page EM-105).
HINT:
Refer to the procedures from the installation of the
air cleaner case up until the installation of the purge
VSV.
Page 1584 of 2000

BRAKE – BRAKE MASTER CYLINDERBR–31
BR
INSTALLATION
(2006/01- )
1. INSTALL BRAKE MASTER CYLINDER SUB-
ASSEMBLY
NOTICE:
• The master cylinder and piston are designed so
that the piston can easily fall out. Prevent this by
making sure that the tip of the master cylinder
points downward when handling the master
cylinder.
• Make sure foreign matter does not attach to the
master cylinder's piston. If foreign matter
attaches, clean it off with a cloth. Then apply
lithium soap base glycol grease to the entire outer
circumference contact surface area of the piston.
(a) Install a new O-ring to the master cylinder.
(b) Install the master cylinder to the booster with the 2
nuts.
Torque: 12.5 N*m (127 kgf*cm, 9 ft.*lbf)
(c) Using SST, connect the 2 brake lines labeled B to
the master cylinder.
SST 09023-00101
Torque: 15.2 N*m (155 kgf*cm, 11 ft.*lbf) without
SST
14 N*m (144 kgf*cm, 10 ft.*lbf) with SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.).
(d) Connect the brake fluid level warning switch
connector labeled A to the master cylinder.
2. FILL RESERVOIR WITH BRAKE FLUID (See page BR-
6)
3. BLEED AIR FROM BRAKE MASTER CYLINDER (See
page BR-7)
4. BLEED AIR FROM BRAKE LINE (See page BR-7)
5. BLEED AIR FROM ABS AND TRACTION ACTUATOR
ASSEMBLY (See page BR-8)
6. CHECK BRAKE FLUID LEVEL IN RESERVOIR (See
page BR-6)
7. CHECK FOR BRAKE FLUID LEAKAGE
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C127053E01