BRAKE MASTER CYLINDER(for LHD) INSTALLATION

PROCEDURE


  1. INSTALL BRAKE MASTER CYLINDER GASKET


    1. Install a new brake master cylinder gasket to the brake master with stroke simulator cylinder assembly.

  2. INSTALL BRAKE MASTER WITH STROKE SIMULATOR CYLINDER ASSEMBLY


    1. B000YUY

      Temporarily install the brake master with stroke simulator cylinder assembly to the body.

      Note


      • Do not kink or damage the No. 2 brake actuator tube.

      • Protect the surface of the relay block so that it does not become damaged on the brake master with stroke simulator cylinder assembly.

    2. B000YVW

      Attach the wire harness clamp.

    3. Connect the brake fluid level warning switch connector.

    4. Install the brake master with stroke simulator cylinder assembly with the 4 nuts.

      Torque:
      12.7 N*m  { 130 kgf*cm, 9 ft.*lbf }

  3. INSTALL PUSH ROD PIN

    Click here

  4. INSTALL STOP LIGHT SWITCH ASSEMBLY

    Click here

  5. INSTALL BRAKE PEDAL RETURN SPRING

    Click here

  6. INSTALL HEATER TO REGISTER CENTER SUB DUCT

    Click here

  7. INSTALL NO. 2 AIR DUCT

    Click here

  8. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY

    Click here

  9. CONNECT BRAKE TUBE


    1. B000WPV

      Using a union nut wrench, connect the brake tube to the brake master with stroke simulator cylinder assembly.

      Torque:
      Specified tightening torque
      15.2 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Note


      • Do not kink or damage the brake tube.

      • Do not allow any foreign matter such as dirt or dust to enter the brake tube from the connecting parts.

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using a union nut wrench (fulcrum length of 22 mm (0.8661 in.)) + torque wrench (fulcrum length of 162 mm (6.3779 in.)): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)

  10. INSTALL BRAKE ACTUATOR WITH BRACKET

    Click here

  11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Click here

  12. BLEED BRAKE SYSTEM

    Click here

  13. INSPECT AND ADJUST BRAKE PEDAL

    Click here

  14. INSPECT FOR BRAKE FLUID LEAK

    Click here

  15. READ VALUE OF ACCUMULATOR PRESSURE SENSOR OUTPUT VOLTAGE

    Tech Tips

    If removing and installing the No. 2 brake actuator tube, check for a brake fluid leak from the No. 2 brake actuator tube connection area by monitoring the accumulator pressure sensor output value from the brake actuator. Directly checking for a brake fluid leak from the No. 2 brake actuator tube connection area is difficult.


    1. Turn the engine switch off.

    2. Connect the GTS to the DLC3.

    3. Turn the engine switch on (IG).

    4. Operate the GTS according to the display and select "DATA LIST".


      Chassis > ABS/VSC/TRAC > Data List
      Tester Display
      Accumulator Sensor
      Skid control ECU
      Tester Display Measurement Item/Range Normal Condition Diagnostic Note
      Accumulator Pressure Sensor Accumulator pressure sensor / min.: 0 V, max.: 5 V Specified value: 2.6 to 3.8 V -
    5. B000TQAC01
      *a Torque Wrench Fulcrum Length

      Depress the brake pedal 4 or 5 times to operatethe pump motor, and check the output value on the GTS with the motor stopped (not braking).

      OK
      Accumulator pressure sensor's output voltage drops 0.2 V or less for 30 seconds.

      If the voltage drops more than 0.2 V, there may be a brake fluid leak from the No. 2 brake actuator tube connection area. Remove the brake actuator and brake accumulator pump, and then repeat the procedures above from the retightening of the 2 union nuts of the No. 2 brake actuator tube.

      Torque:
      Specified tightening torque
      15.2 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using a union nut wrench (fulcrum length of 22 mm (0.8661 in.)) + torque wrench (fulcrum length of 162 mm (6.3779 in.)): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)

  16. CHECK BRAKE MASTER CYLINDER WITH GTS

    Click here

  17. CHECK MASTER CYLINDER PRESSURE SENSOR SIGNAL

    Click here