Page 817 of 4331

B
R
N
O P
C
AUTIO N:
W hile w ork in g, c o ver p rim ary p is to n r o d w it h c lo th t o p re ven t it f r o m b ein g d am ag ed .
1 . Secu re fla nge o f c yli n der b ody in v is e a s s h ow n.
C AUTIO N:
• Use c o pper p la te o r c lo th t o c o ver f la n ge w hen s ecu rin g
i n v is e.
• W hen s ecu rin g m aste r c ylin der a ssem bly in a v is e, b e
s u re n ot t o o ver-tig hte n .
2 . Usin g a p in -p unch [c o m merc ia l s e rv ic e to ol: d ia m ete r a ppro x. 4
m m ( 0 .1 6 in )], r e m ove p in f r o m r e se rv o ir ta nk.
3 . Rem ove m aste r c ylin der a sse m bly fr o m v is e .
4 . Rem ove r e se rv o ir ta nk a nd g ro m met fr o m c ylin der b ody.
5 . While p ush in g p rim ary p is to n, r e m ove p is to n s to pper th ro ugh
s e co ndary ta nk b oss h ole in th e c ylin der b ody.
6 . Rem ove s n ap r in g w it h p ush in g p rim ary p is to n.
C AUTIO N:
B e c are fu l n ot t o p op o u t p is to n .
7 . Hold in g r o d o f p rim ary p is to n, r e m ove p rim ary p is to n a sse m bly ,
p la te a nd g uid e a sse m bly b y p ull in g s tr a ig ht to p re ve nt p is to n
c u p fr o m b ein g c a ught b y th e in ner w all o f c ylin der.
8 . Rem ove p la te a nd g uid e a sse m bly fr o m p rim ary p is to n.
C AUTIO N:
B e c are fu l n ot t o d am ag e r o d f r o m t h e in ner w all o f p la te . W
FIA 051 5E W
FIA 051 6E B
R A056 1D W
FIA 051 7E
Page 818 of 4331
Page 819 of 4331

BR
N
O P
5. Be careful not to damage rod of primary piston with the cloth.
Then insert snap ring to cylinder body while pushing primary pis-
ton.
CAUTION:
Make sure that snap ring is securely engaged in cylinder
body inner diameter groove.
6. Apply brake fluid to a grommet, and press it into reservoir tank to install.
7. Install reservoir tank to cylinder body. CAUTION:
Pay attention to the orientatio n of reservoir tank. Make sure
reservoir tank is fully seated on master cylinder.
8. Secure flange of cylinder body in vise as shown. CAUTION:
• Use copper plate or cloth to cover flange for securing in
the vise.
• When securing master cylinder assembly in a vise, be sure not to over-tighten.
• Be sure to secure the flange part with the brake tube
installation side of cylinder body facing up (chamfered pin
insert hole of cylinder body facing up).
9. Using a pin punch [commercial service tool: diameter approx. 4 mm (0.16 in)], insert the reservoir tank pin into the pin hole. WFIA0515E
Page 820 of 4331
Page 821 of 4331

BRAKE BOOSTER
BR-21
< SERVICE INFORMATION >
C
D E
G H
I
J
K L
M A
B BR
N
O P
Removal and Installation
INFOID:0000000004305905
REMOVAL CAUTION:
• Be careful not to splash brake fluid on painte d areas such as body. It may cause paint damage. If
brake fluid is splashed on painte d surfaces of body, wipe them with cloth immediately and then wash
it away with water.
• Be careful not to deform or bend brake tub es while removing and installing brake booster.
• Replace clevis pin if it is damaged.
• Be careful not to damage brake booster stud bolt thr eads. If brake booster is tilted or inclined during
installation, dash panel may damage the threads.
1. Remove vacuum hose from brake booster.
2. Remove master cylinder assembly. Refer to BR-15, " Removal and Installation " .
3. Remove snap pin and clevis pin on the clevis of the brake booster, and disconnect the input rod from the brake pedal. 1. Reservoir tank 2. Master cylinder 3. Brake booster
4. Clevis 5. Spacer 6. Gasket Up AWFIA0530GB
SFIA2044E
Page 822 of 4331
Inspection and Adjustment " .
7. Tighten lock nut of input rod to the specified torque.
8. Install vacuum hose into brake booster. Refer to BR-23, " Removal and Installation " .
9. Bleed the air from the brake hydraulic system. Refer to BR-9, " Bleeding Brake System " .
Input rod length (B) : Refer to
BR-40, " Brake Booster " .
Page 823 of 4331

BR
N
O P
VACUUM LINES
Component INFOID:0000000004305906
Removal and Installation INFOID:0000000004305907
REMOVAL 1. Disconnect the vacuum hose from the intake manifold.
2. Disconnect the vacuum hose from the brake booster.
3. Disconnect the vacuum hose from the clip and re move the vacuum hose and vacuum tube assembly.
INSTALLATION Installation is in the reverse order of removal.
CAUTION:
• Because the vacuum hose at the intake manifold contai ns a built-in check valve, it must be installed
in the correct orientation. Refer to the stamp or label to confirm correct installation orientation.
Brake booster will not operate normally if ho se is installed in the reverse orientation.
• Insert vacuum hose at least 24 mm (0.94 in) on to the vacuum tube and vacuum fittings on the brake booster and intake
manifold as shown.
• Never use lubricating oil during assembly.
Inspection INFOID:0000000004305908
VISUAL INSPECTION Check for improper installation, damage and deterioration. Replace parts as necessary.
CHECK VALVE INSPECTION 1. Hose clamp 2. Engine side indicator stamp (for
built-in check valve orientation)3. Vacuum hose
4. Clip 5. Clip position stamp 6. Vacuum tube
A. To intake manifold B. To brake booster SBR225B
Page 824 of 4331
" Check Valve " .
When connected to engine side (2) : Refer to BR-39, " Check Valve " .