[35A] BASIC BRAKE SYSTEM - - MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER - REMOVAL AND INSTALLATION | PRINT PAGE / INDEX / PRIOR / NEXT

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER

REMOVAL AND INSTALLATION
Pre-removal Operation Air Intake Hose and Air Cleaner Removal (Refer to GROUP 15, Air Cleaner or ). <LH drive vehicles> Battery Tray Removal <RH drive vehicles> Brake Fluid Draining | Post-installation Operation Brake Fluid Supplying and Air Bleeding (Refer to ). Brake Pedal Adjustment (Refer to ). Battery Tray Installation <RH drive vehicles> Air Intake Hose and Air Cleaner Installation (Refer to GROUP 15, Air Cleaner or ). <LH drive vehicles>
|  |  | Master cylinder removal steps
--- | --- | --- | ---
|  | 1. | Brake fluid level sensor connector
<<A>> | >>D<< | 2. | Reservoir protector <2000-DOHC>
|  | 3. | Reservoir cap assembly
|  | 4. | Reservoir
|  | 5. | Brake fluid level sensor
| >>C<< | 6. | Reservoir hose
|  | 7. | Brake pipe connection
|  | 10. | Bracket <LH drive vehicles>
|  | 11. | Master cylinder
|  |  | Proportioning valve removal steps
|  | 7. | Brake pipe connection
|  | 8. | Proportioning valve <vehicles without ABS>
|  | 9. | O-ring <vehicles without ABS>
|  |  | Brake booster removal steps
|  | 1. | Brake fluid level sensor connector
|  | 7. | Brake pipe connection
|  | 10. | Bracket <LH drive vehicles>
|  | 11. | Master cylinder
| >>B<< | • | Push rod protrusion amount check and adjustment
| >>A<< | 12. | Vacuum hose (with built-in check valve)
|  | 13. | Snap pin
|  | 14. | Pin assembly
|  | 15. | Brake booster
|  | 16. | Sealer
|  |  | Fitting removal steps
| >>A<< | 12. | Vacuum hose (with built-in check valve)
|  | 17. | Fitting
| REMOVAL SERVICE POINT
| <<A>> RESERVOIR PROTECTOR REMOVAL <2000-DOHC>
| Disengage the claw of arrow 1 and arrow 2 in sequence, then remove the reservoir protector.
| INSTALLATION SERVICE POINTS
| >>A<< VACUUM HOSE CONNECTION
| Insert vacuum hose with its paint mark facing upward.
| >>B<< PUSH ROD PROTRUSION AMOUNT CHECK AND ADJUSTMENT
| Use the vacuum pump to measure dimension "A" applying a negative pressure of 66.7 kPa to the brake booster. Standard value (A): 10.15 - 10.40 mm NOTE: When a negative pressure of 66.7 kPa is not applied to the brake booster, the push rod protrusion amount (A) should be 8.85 - 9.10 mm.
| If the protrusion amount is not within the standard value range, adjust the push rod length by turning the push rod. Use the special tool push rod adjusting socket (MB991568) to turn the push rod while holding the rod spline with angle-nose pliers.
| >>C<< RESERVOIR HOSE CONNECTION
| Insert the reservoir hose with its paint mark facing front of the vehicle.
| >>D<< RESERVOIR PROTECTOR INSTALLATION <R.H. DRIVE VEHICLES>
| Install the reservoir protector with its arrow mark facing behind the vehicle.

[35A] BASIC BRAKE SYSTEM - - MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER - REMOVAL AND INSTALLATION | PRINT PAGE / INDEX / PRIOR / NEXT

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