Brake Master Cylinder Assembly Removal and Installation
Precautions: Precautions for Brake Service · Precautions for Brakes · General safety (00)
NOTICE:
•The brake master cylinder and brake booster will lose their original performance if they are disassembled and reassembled.
If any faulty condition is found in the brake master cylinder or brake booster, replace the part rather than trying to disassemble and repair it.
•Brake fluid is extremely damaging to painted surfaces. If brake fluid contacts painted surfaces, immediately wipe it off and flush the surfaces with water thoroughly.
If any faulty condition is found in the brake master cylinder or brake booster, replace the part rather than trying to disassemble and repair it.
•Brake fluid is extremely damaging to painted surfaces. If brake fluid contacts painted surfaces, immediately wipe it off and flush the surfaces with water thoroughly.
Removal
1)For D16AA-LHD model, remove air cleaner assembly. 
2)For D16AA-RHD model, remove engine assembly.
3)Clean external surface of brake master cylinder.
4)Disconnect brake fluid level switch connector (1) on reservoir.
5)Drain brake fluid in reservoir.
6)For M/T model, disconnect clutch reservoir hose from reservoir.
7)Using special tool, loosen flare nuts and disconnect brake pipes (1) from brake master cylinder.
8)Remove brake master cylinder fixing nuts (2).
9)Remove brake master cylinder (1) and O-ring (2).
Installation
1)Install new O-ring (2) to brake master cylinder assembly (1).
2)Install brake master cylinder to brake booster.
3)Tighten brake master cylinder fixing nuts to specified torque.
4)Connect brake pipes (1) to brake master cylinder and tighten flare nuts to specified torque.
Brake pipe flare nut (M12) (b): 19 N·m (1.9 kgf-m, 14.0 lbf-ft)
Tightening torque
Brake pipe flare nut (M10) (b): 16 N·m (1.6 kgf-m, 12.0 lbf-ft)Brake pipe flare nut (M12) (b): 19 N·m (1.9 kgf-m, 14.0 lbf-ft)
5)For M/T model, connect clutch reservoir hose to reservoir.
6)Connect brake fluid level switch connector.
7)For D16AA-LHD model, install air cleaner assembly.
8)For D16AA-RHD model, install engine assembly.
9)Bleed brake system.
10)Check installed parts for brake fluid leakage.
11)Check brake pedal for play.
12)Check that brake system operates properly without fluid leakage.