BRAKE MASTER CYLINDER(for TMMF Made RHD) REASSEMBLY

PROCEDURE


  1. INSTALL MASTER CYLINDER RESERVOIR GROMMET


    1. Apply lithium soap base glycol grease to 2 new master cylinder reservoir grommets.

    2. Install the 2 master cylinder reservoir grommets onto the brake master cylinder reservoir.

  2. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY (except 2ZR-FE)

    B0045XCE01

    1. When installing a new brake master cylinder reservoir assembly, cut out the clutch tube tip of the brake master cylinder reservoir assembly as shown in the illustration (for Manual Transaxle).

      Text in Illustration
      *a More than 27 mm (1.06 in.)

      Note


      • Do not allow any foreign matter to enter the brake master cylinder reservoir assembly.

      • Make sure that fluid supply is not affected by cutting tube.

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

    3. B0046M9

      Using "TORX" socket wrench T20, install the screw.

      Torque:
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

  3. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY (for 2ZR-FE)


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

    2. Fix the brake master cylinder body in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    3. B0045KM

      Using a 5 mm pin punch and a hammer, tap in the straight pin.

    4. Remove the brake master cylinder assembly from the vise.

  4. INSTALL BRAKE TUBE WAY (for 2ZR-FE)


    1. B0045A4

      Temporarily install the brake tube way with the 2 bolts, 2 nuts and 4 washers.

  5. INSTALL FRONT NO. 1 BRAKE TUBE UNION (for 2ZR-FE)


    1. Fix the brake master cylinder body in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. B00465S

      Temporarily install the front No. 1 brake tube union and 2 new gasket with a new union bolt.

  6. INSTALL BRAKE MASTER CYLINDER TO WAY TUBE (for 2ZR-FE)


    1. B0046XZ

      Temporarily install the brake master cylinder to way tube.

    2. Tighten the union bolt.

      Torque:
      38.5 N*m  { 393 kgf*cm, 28 ft.*lbf }

    3. Using a union nut wrench 12 mm, tighten the 2 union nuts.

      Torque
      19.6 N*m (200 kgf*cm, 14 ft.*lbf)

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench.

      Click here

    4. Remove the brake master cylinder assembly from the vise.

    5. Remove the 2 bolts, 2 nuts and 4 washers.