Brake Master Cylinder: Service and Repair

Brake Master Cylinder and Servo Unit Replacement

NOTICE
Do not spill brake fluid on the vehicle; it may damage the paint. If brake fluid gets on the paint, wash it off immediately with water.

NOTE:

- After removal, plug the ends of the hoses and the joints to prevent spilling brake fluid.
- The illustrations show with ABS.

1. Remove the air cleaner Service and Repair.

2. Remove the IMA system power cable clamps (A).





3. Remove the reservoir cap (B), and remove the brake fluid Service and Repair.

4. Remove the reservoir tank mounting bolt (A).






5. Remove the wire harness clamps (A).





6. Disconnect the wire harness connector (B) and the locked connector (C) by pulling down the lever (D).

7. Remove the reservoir tank bracket (A).






8. Remove the wire harness clamps stay (A).






9. Disconnect the brake lines (A) from the master cylinder (B).





10. Disconnect the suction hose (C) from the brake line (D).

11. Disconnect the brake fluid level switch connector (E).

12. Disconnect the brake line (A) from the servo unit (B).






13. Disconnect the servo unit 25P connector (A) by pulling down the lock (B).






14. Remove the brake lines (A) from the clamp (B).






15. Disconnect the brake lines (A) from the ABS or VSA modulator-control unit (B).






16. Remove the lock pin (A) and the clevis pin (B), then disconnect the yoke (C) from the brake pedal.





17. Remove the servo unit mounting nuts (D).

18. Remove the servo unit (A) with master cylinder from the engine compartment.

NOTE:

- Be careful not to bend or damage the brake lines.
- Use the new servo unit gasket (B) during reassembly.





19. Remove the subreservoir (A) and the reservoir grommets (B) from the servo unit (C) with the master cylinder (D).

NOTE: When removing the subreservoir, replace the reservoir grommets with new ones.






20. Remove the master cylinder mounting bolts (A), and separate the master cylinder (B) from the servo unit (C).






21. Install the master cylinder and the servo unit in the reverse order of removal, and note these items:

- Coat the new O-ring with the Shin-Etsu silicone grease (P/N 08798-9013).
- Make sure not to get any silicone grease on the terminal part of the connectors and switches, especially if you have silicone grease on your hands or gloves.
- Check the brake pedal height and free play, and adjust it if necessary Adjustments.

22. Do the normal brake system bleeding (except servo unit and power unit).

23. Do the servo unit and power unit system bleeding.

24. Spin the wheels to check for brake drag.

25. Do the sensor 0 (zero) position memorization Programming and Relearning.