BRAKE MASTER CYLINDER(for LHD) REASSEMBLY

PROCEDURE


  1. INSTALL MASTER CYLINDER PUSH ROD CLEVIS


    1. Temporarily install the lock nut and master cylinder push rod clevis to the brake master cylinder assembly.

      Note

      Tighten the lock nut when adjusting the brake pedal height.

  2. INSTALL BRAKE STROKE SIMULATOR BRACKET


    1. B004W0L

      Install the brake stroke simulator bracket to the brake master cylinder sub-assembly with the 3 bolts.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  3. INSTALL NO. 1 BRAKE ACTUATOR TUBE


    1. B004TPAC01
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench

      Using a union nut wrench, connect the No. 1 brake actuator tube to the brake master cylinder sub-assembly.

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

      Note


      • Do not kink or damage the No. 1 brake actuator tube.

      • Do not allow any foreign matter such as dirt or dust to enter the No. 1 brake actuator 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)

  4. INSTALL BRAKE MASTER CYLINDER TUBE


    1. B004WLY

      Temporarily install the brake master cylinder tube to the brake master cylinder sub-assembly.

  5. INSTALL BRAKE STROKE SIMULATOR CYLINDER SUB-ASSEMBLY


    1. B004TS3C01
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench

      Install the brake stroke simulator cylinder sub-assembly to the brake stroke simulator bracket with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    2. Temporarily install the brake master cylinder tube to the brake master cylinder sub-assembly.

    3. Using a union nut wrench, tighten the brake master cylinder tube.

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

      Note


      • Do not kink or damage the brake master cylinder tube.

      • Do not allow any foreign matter such as dirt or dust to enter the brake master cylinder 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)

  6. INSTALL MASTER CYLINDER RESERVOIR GROMMET


    1. B004YLPC01
      B004TUP Lithium Soap Base Glycol Grease

      Apply a light coat of lithium soap base glycol grease to the entire circumference of 2 new master cylinder reservoir grommets.

    2. Install the 2 master cylinder reservoir grommets to the brake master cylinder body.

  7. INSTALL BRAKE MASTER CYLINDER RESERVOIR STRAINER

  8. INSTALL BRAKE MASTER CYLINDER RESERVOIR FILLER CAP ASSEMBLY

  9. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY


    1. B004UFM

      Secure the brake master cylinder in a vise.

      Note

      Place aluminum plates on the vise to prevent damage to the brake master cylinder.

    2. Install the brake master cylinder reservoir assembly to the brake master cylinder body.

    3. Using a pin punch and hammer, install a pin to the brake master cylinder reservoir assembly.

  10. INSTALL NO. 1 BRAKE ACTUATOR BRACKET


    1. B004S6T

      Install the No. 1 brake actuator bracket to the brake booster with accumulator pump assembly with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  11. INSTALL TUBE CLAMP BRACKET


    1. B004YTN

      Install the tube clamp bracket to the brake booster with accumulator pump assembly with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  12. INSTALL BRAKE BOOSTER WITH ACCUMULATOR PUMP ASSEMBLY


    1. B004TLK

      Install the brake booster pump bush and brake booster pump collar to the brake stroke simulator bracket.

    2. Install the 2 brake booster pump bushes and 2 brake booster pump collars to the brake booster with accumulator pump assembly.

    3. B004SCW

      Install the brake booster with accumulator pump assembly to the brake master with stroke simulator cylinder assembly with the nut.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
    4. B004WS3

      Connect the No. 2 brake actuator hose to the brake booster with accumulator pump assembly, brake master cylinder reservoir assembly and slide the clamp to secureit.

    5. B004TQ6

      Install the brake actuator case with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    6. Attach the clip.

  13. INSTALL NO. 2 BRAKE ACTUATOR TUBE


    1. B004UCPC03
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench

      Temporarily install the No. 2 brake actuator tube to the brake booster with accumulator pump assembly.

      Note


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

      • Do not allow any foreign matter such as dirt or dust to enter the No. 2 brake actuator tube from the connecting parts.

    2. Install the tube clamp with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    3. Using a union nut wrench, tighten the No. 2 brake actuator tube.

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

      Note


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

      • Do not allow any foreign matter such as dirt or dust to enter the No. 2 brake actuator 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)

  14. INSTALL RESERVOIR BRACKET


    1. B004RLD

      Install the reservoir bracket to the brake master with stroke simulator cylinder assembly with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    2. B004WOL

      Connect the connector.

    3. Attach the 2 claws to connect the wire harness to the brake master cylinder reservoir assembly.

    4. Attach the connector clamp.