MASTER CYLINDER REMOVAL/INSTALLATION [R.H.D.]

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Caution
•  When removing/installing the master cylinder, be careful not to spill brake fluid on the power brake unit vacuum sensor. Otherwise, brake fluid may get on the power brake unit vacuum sensor and damage it.
•  Brake fluid will damage painted surfaces. Be careful not to spill any on painted surfaces. In addition, if there is any brake fluid on the wiring harness, the wire insulation may corrode causing a malfunction such as a short circuit. If brake fluid gets on a painted surface or wiring harness, wash and flush it off completely with water immediately.
Note
•  Tighten the brake pipe flare nut using any commercially available flare nut wrench.

1.  Disconnect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 2.0, SKYACTIV-G 2.5].) (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT i-stop)].) (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-D 2.2].)

2.  For SKYACTIV-G 2.0 or SKYACTIV-G 2.5, perform the following procedure:

(1)  Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5].)
(2)  Remove the cooler hose (LO) installation nut. (See REFRIGERANT LINE REMOVAL/INSTALLATION.)
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(3)  Detach the cooler hose (LO) from the clip.

3.  For SKYACTIV-D 2.2, perform the following procedure:

(1)  Remove the windshield wiper arm and blade. (See WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION.)
(2)  Remove the cowl grille. (See COWL GRILLE REMOVAL/INSTALLATION.)
(3)  Remove the windshield wiper motor and link. (See WINDSHIELD WIPER MOTOR AND LINK REMOVAL/INSTALLATION.)
(4)  Remove the cowl panel. (See COWL PANEL REMOVAL/INSTALLATION.)

4.  Remove in the order indicated in the table.

5.  If the master cylinder component is replaced as a single unit, adjust the power brake unit rod. (See Rod Adjustment Note.)

6.  Install in the reverse order of removal.

7.  After installation, add brake fluid, bleed the air, and inspect for fluid leakage. (See BRAKE FLUID AIR BLEEDING.)

SKYACTIV-G 2.0, SKYACTIV-G 2.5

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1
Brake fluid level sensor connector
2
Clutch reserve hose (MTX)
(See Clutch Reserve Hose Removal Note (MTX).)
(See Clutch Reserve Hose Installation Note (MTX).)
3
Brake pipe
4
Nut
5
Master cylinder component
6
Cap

SKYACTIV-D 2.2

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1
Brake fluid level sensor connector
2
Clutch reserve hose (MTX)
(See Clutch Reserve Hose Removal Note (MTX).)
(See Clutch Reserve Hose Installation Note (MTX).)
3
Brake pipe
4
Nut
5
Master cylinder component
6
Cap


Rod Adjustment Note

1.  Install the plate as shown in the figure and verify that the clearance between the rod end and the plate is within the standard.

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Standard A
0 mm {0 in}
•  If not within the standard, adjust the rod position using the following procedure.
(1)  Install the SST as shown in the figure.
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(2)  Rotate the socket wrench in either direction with the SST secured to adjust the rod position.
Note
•  When the socket wrench is rotated clockwise as viewed from the front of the vehicle, the rod moves towards the rear of the vehicle.
•  When the socket wrench is rotated counterclockwise as viewed from the front of the vehicle, the rod moves towards the front of the vehicle.
•  The rod moves back and forth approx. 1 mm for each rotation.
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Clutch Reserve Hose Removal Note (MTX)

1.  Disconnect the clutch reserve hose in the order shown in the figure.

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Clutch Reserve Hose Installation Note (MTX)

1.  Insert the clutch reserve hose to the master cylinder.

2.  Pull the clutch reserve hose to verify that it does not come off, and reinsert it completely.