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MASTER CYLINDER REMOVAL/INSTALLATION

BME041143400201

1. For L.H.D. model, remove the air cleaner. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [L3].) (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [AJ].) (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

2. For the MZR-CD (RF Turbo) engine model, remove the fuel filter installation bolt and put the fuel filter aside. (See FUEL FILTER COMPONENT REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

3. Remove in the order indicated in the table.

R.H.D.

L.H.D.

1 | Brake fluid level sensor connector
2 | Brake pipe
3 | Master cylinder (See Master Cylinder Installation Note)

4. Install in the reverse order of removal.

## Master Cylinder Installation Note

### Measure the clearance B and C

1. Loosen the adjusting nut of the SST.

2. Place the SST on the power brake unit and tighten the nut and washer.

Tightening torque

  9.9-15.6 N·m {100-160 kgf·cm, 87-138 in·lbf}

3. Apply 66.7 kPa {500 mmHg, 19.7 inHg} vacuum to the power brake unit using a vacuum pump.

4. Turn the adjusting nut of the SST counterclockwise until the gauge rod just contacts the push rod end of the power brake unit.

5. Push lightly on the end of the gauge rod to be sure it is seated.

6. Verify that there is no gap between the adjusting nut and SST body.

7. Remove the SST from the power brake unit without disturbing the adjusting nut.

8. Set the SST onto the master cylinder as shown in the figure.

9. Push lightly on the end of the SST gauge rod to be sure that it is contacting the bottom of the master cylinder piston, but do not push so hard that the piston moves.

10. Note any clearance between the SST body and the adjusting nut (clearance B), or between the body and the master cylinder (clearance C).

11. Adjust the push rod as necessary as outlined in "Adjustment" below.

Adjustment

Measurement | Push rod
--- | ---
Clearance B | Too long
Clearance C | Too short
No clearance at B or C | Too long

### Clearance at B or no clearance at B or C

1. Measure and record the height D1 of the gauge rod.

2. Turn the adjusting nut until the SST body sets closely on the master cylinder.

3. Turn only enough for the body to touch.

4. Measure and record height D2 of the gauge rod.

5. Subtract D1 from D2 and add 0.1-0.4 mm {0.004-0.016 in}. Using the SST, turn the nut to shorten the power brake unit push rod an amount equal to the sum.

### Clearance at C

1. Push lightly on the end of the SST gauge rod, and measure the clearance between the adjusting nut and the SST body.

2. Using the SSTs, turn the nut to lengthen the power brake unit push rod an amount equal to the sum, substracting 0.1-0.4 mm {0.004-0.016 in} from the clearance measured at B.