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BRAKE MASTER CYLINDER
BR-25
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BRAKE MASTER CYLINDER
Exploded ViewINFOID:0000000003811194
Removal and InstallationINFOID:0000000003811195
REMOVAL
CAUTION:
Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it
off immediately and wash with water if it gets on a painted surface.
1. Drain brake fluid. Refer to BR-9, "
Draining".
2. Remove air duct and air cleaner case. Refer to EM-26, "
Exploded View".
3. Separate the brake fluid level switch harness connector and harness clip.
4. Separate the brake tubes from the master cylinder assembly with a flare nut wrench.
CAUTION:
Never scratch the flare nut and the brake tube.
5. Remove the master cylinder assembly.
CAUTION:
Depress the brake pedal several times to release the vacuum pressure from the brake booster.
Then remove the master cylinder assembly.
Never depress the brake pedal after the master cylinder assembly is removed.
The piston of the master cylinder assembly is exposed. Never damage it when removing the
master cylinder.
1. Reservoir cap 2. Oil strainer 3. Reservoir tank
4. Cylinder body 5. Pin 6. O-ring
7. Grommet
: Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease.
: Apply brake fluid.
Refer to GI-4, "
Components" for symbols not described on the above.
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BR-26
< ON-VEHICLE REPAIR >
BRAKE MASTER CYLINDER
The piston may drop off when pulled out strongly. Never hold the piston. Hold the cylinder body
when handling the master cylinder assembly.
INSTALLATION
CAUTION:
Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it
off immediately and wash with water if it gets on a painted surface.
Note the following, and install the reverse order of removal.
Never depress the brake pedal after the master cylinder assembly is removed.
Apply PBC (Poly Butyl Cuprysil) silicone-based grease to the
brake booster [see (A) in the figure] when installing the master cyl-
inder assembly to the brake booster.
The piston of the master cylinder assembly is exposed. Never
damage it when handling the master cylinder and check that no dirt
and dust are present on the piston before installation. Clean it with
new brake fluid if necessary.
The piston may drop off when pulled strongly. Never hold the pis-
ton. Hold the cylinder body when handling the master cylinder
assembly.
Temporarily tighten the brake tube flare nut to the master cylinder
assembly by hand. Then tighten it to the specified torque with a
crowfoot and torque wrench. Refer to BR-19, "
FRONT : Exploded View".
CAUTION:
Never scratch the flare nut and the brake tube.
After installation, perform the air bleeding. Refer to BR-10, "
Bleeding Brake System".
CAUTION:
Never reuse drained brake fluid.
Disassembly and AssemblyINFOID:0000000003811196
DISASSEMBLY
CAUTION:
Never disassemble the cylinder body.
Remove the reservoir tank if necessary.
1. Fix the master cylinder assembly to a vise.
CAUTION:
Always set copper plates or cloth between vise when fixing the cylinder body to a vise. Never
overtighten the vise.
2. Remove the reservoir tank mounting pin with a pin punch.
3. Remove the reservoir tank and grommet from the cylinder body.
CAUTION:
Never drop the removed parts. The parts must not be
reused if they are dropped.
ASSEMBLY
1. Apply new brake fluid to the grommet and install it to the cylinder body.
CAUTION:
Never use mineral oil such as gasoline or light oil.
Never reuse the grommets.
2. Install the reservoir tank to the cylinder body.
CAUTION:
Never drop the parts when installing. The parts must not be reused if they are dropped.
Never reuse reservoir tank.
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BRAKE MASTER CYLINDER
BR-27
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3. Fix the cylinder body to a vise.
CAUTION:
Place the reservoir tank with the chamfered pin hole ( )
facing up.
Always set copper plates or cloth between vise when fix-
ing the cylinder body to a vise. Never overtighten the vise.
4. Tilt the reservoir tank so that a mounting pin can be inserted.
Insert a mounting pin. Return the reservoir tank to the horizontal
position. Insert another mounting pin into the pin hole on the
opposite side in the same manner after the mounting pin passes
through the cylinder body pin hole.
CAUTION:
Never reuse the mounting pin.
InspectionINFOID:0000000003811197
INSPECTION AFTER INSTALLATION
Fluid Leak
Check for brake fluid leakage from the cylinder body-to-brake booster mounting face, reservoir tank mounting
face and brake tube connections.
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BR-28
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BRAKE BOOSTER
BRAKE BOOSTER
Exploded ViewINFOID:0000000003811198
Removal and installationINFOID:0000000003811199
REMOVAL
1. Remove brake master cylinder assembly. Refer to BR-25, "Exploded View".
CAUTION:
Depress the brake pedal several times to release the vacuum pressure from the brake booster.
Then remove the master cylinder assembly.
Never depress the brake pedal after the master cylinder assembly is removed.
The piston of the master cylinder assembly is exposed. Never damage it when removing the
master cylinder.
The piston may drop off when pulled out strongly. Never hold the piston. Hold the cylinder body
when handling the master cylinder assembly.
2. Remove vacuum hose from brake booster. Refer to BR-31, "
Exploded View".
3. Remove snap pin (1) and clevis pin (2) from inside vehicle.
4. Remove nuts on brake booster and brake pedal assembly.
CAUTION:
Hold the brake booster so as to avoid dropping out.
5. Remove brake tube bracket and fuel feed tube bracket.
6. Remove brake booster from dash panel in engine room side.
CAUTION:
Never deform or bend the brake tubes.
NOTE:
If removing brake booster is difficult, remove clevis from brake
booster.
INSTALLATION
Note the following, and installation is the reverse order of removal.
Be careful not to damage brake booster stud bolt threads. If brake booster is tilted during installation, the
dash panel may damage the threads.
Never deform or bend the brake tubes when installing the brake booster.
Always use a new gasket between the brake booster.
1. Master cylinder assembly 2. Brake booster 3. Lock nut
4. Clevis 5. Gasket
Refer to GI-4, "
Components" for symbols in the figure.
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BRAKE BOOSTER
BR-29
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Replace the clevis pin if it is damaged. Refer to BR-18, "Inspection and Adjustment".
After installation, perform the air bleeding. Refer to BR-10, "
Bleeding Brake System".
CAUTION:
Never reuse drained brake fluid.
Inspection and AdjustmentINFOID:0000000003811200
INSPECTION AFTER REMOVAL
Output Rod Length Inspection
1. With a handy vacuum pump, apply vacuum pressure of −66.7
kPa (−500 mmHg, −19.70 inHg, –0.667 bar) to the brake
booster.
2. Check the output rod length (A).
Input Rod Length Inspection
1. Loosen the lock nut (1) and adjust the input rod (2) to the speci-
fied length (B).
2. Tighten the lock nut to the specified torque.
INSPECTION AFTER INSTALLATION
Operation
Depress the brake pedal several times at 5-second intervals with the
engine stopped. Start the engine with the brake pedal fully
depressed. Check that the clearance between brake pedal and dash
lower pane decreases.
NOTE:
A slight impact with a small click may be felt on the pedal when the
brake pedal is fully depressed. This is a normal phenomenon due to
the brake system operation.
Air Tight
Standard
A: Refer to BR-45, "
Brake Booster".
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Standard
B: Refer to BR-45, "
Brake Booster".
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BR-30
< ON-VEHICLE REPAIR >
BRAKE BOOSTER
Idle the engine for 1 minute to apply vacuum to the brake booster,
and stop the engine. Then depress the brake pedal several times
at 5-second intervals until the accumulated vacuum is released to
atmospheric pressure. Check that the clearance between brake
pedal and dash lower panel gradually increases (A → B → C) each
time the brake pedal is depressed during this operation.
Depress the brake pedal with the engine running. Then stop the
engine while holding down the brake pedal. Check that the brake
pedal stroke does not change after holding down the brake pedal
for 30 seconds or more.
NOTE:
A slight impact with a small click may be felt on the pedal when the
brake pedal is fully depressed. This is a normal phenomenon due
to the brake system operation.
ADJUSTMENT AFTER INSTALLATION
Perform the brake pedal adjustment after installing the brake pedal assembly. Refer to BR-6, "Inspection and
Adjustment".
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Page 927 of 5121

VACUUM LINES
BR-31
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VACUUM LINES
Exploded ViewINFOID:0000000003811201
Removal and InstallationINFOID:0000000003811202
REMOVAL
Remove the vacuum hose and tube.
INSTALLATION
Note the following, install the vacuum hose and tube.
Because vacuum hose contains a check valve, it must be installed in the correct position. Refer to the stamp
to confirm correct installation. Brake booster will not operate normally if the hose is installed in the wrong
direction.
When installing vacuum hose, insert it until its tip reaches the
back-end of length (A) or further as shown in the figure.
- Face the marking side up when assembling of vacuum hose. (For
both side of vacuum hose of intake manifold side.)
- Face the marking side vehicle front when assembling of vacuum
hose. (For both side of vacuum hose of brake booster side)
CAUTION:
Never use lubricating oil during assembly.
InspectionINFOID:0000000003811203
INSPECTION AFTER REMOVAL
Appearance
Check for correct assembly, damage and deterioration.
Check Valve Airtightness
1. Vacuum hose (built in orifice) 2. Clamp 3. Vacuum tube
4. Vacuum hose (built in check valve)
A. To brake booster B. Paint mark C. Stamp indicating orifice direction
D. Stamp indicating engine direction E. To intake manifold
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Standard
A : 24 mm (0.95 in) or more
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Page 928 of 5121
BR-32
< ON-VEHICLE REPAIR >
VACUUM LINES
Use a handy vacuum pump (A) to check.
Replace vacuum hose assembly if vacuum hose and check valve
are malfunctioning.When connected to the brake booster side (B)
: Vacuum should decrease within 1.3 kPa (10 mmHg,
0.39 inHg, 0.013 bar) for 15 seconds under a vacuum
of −66.7 kPa (−500 mmHg, −19.70 inHg, −0.667 bar).
When connected to the engine side (C):
: Vacuum should not exist.
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