BRAKE MASTER CYLINDER INSTALLATION


  1. INSTALL BRAKE MASTER LESS RESERVOIR TANK CYLINDER SUB-ASSEMBLY

    Note


    • The master cylinder requires careful handling. Do not allow the master cylinder to receive any impact, such as from being dropped. Do not reuse a master cylinder that has been dropped.

    • Do not strike or pinch the master cylinder piston, and do not cause any damage to the master cylinder piston by any other means.

    • Release the vacuum from the booster by depressing the brake pedal several times. Then remove the brake master cylinder from the brake booster.

    • When installing the brake master cylinder sub-assembly onto the brake booster, or when removing the brake master cylinder sub-assembly from the brake booster, make sure that the brake master cylinder sub-assembly is kept horizontal or its tip faces downward (the piston faces upward) to prevent the master cylinder piston from falling off.

    • Do not allow any foreign objects to contaminate the master cylinder piston. If a foreign object gets on the piston, remove it by using a piece of cloth and then apply an even layer of lithium soap based glycol grease around the circumference (sliding part) of the piston.

    • Do not use any other type of grease or fluid.

    Tech Tips

    It is not necessary to adjust the brake push rod when replacing the brake master cylinder assembly.


    1. Install a new O-ring onto the brake master less reservoir tank cylinder sub-assembly.

    2. Install the wire harness clamp bracket and the brake master less reservoir tank cylinder sub-assembly with the 2 nuts.

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }

    3. Connect the 2 master cylinder reservoir tubes with the 2 clips.

    4. Using a 12 mm union nut wrench, install the 2 brake tubes onto the brake master less reservoir tank cylinder sub-assembly.

      Torque:
      24 N*m  { 245 kgf*cm, 18 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.

    5. Install the wire harness onto the wire harness clamp bracket with the bolt.

  2. REMOVE OIL RESERVOIR TANK COVER LH


    1. A01CIYJ

      Disengage the 4 claws and 3 guides and remove the oil reservoir tank cover LH.

  3. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH


    1. A01CHYB

      Detach the 5 clips and remove the lower instrument panel finish panel sub-assembly.

    2. Disconnect each connector.

  4. FILL RESERVOIR WITH BRAKE FLUID


    1. A01CHDW

      Fill the reservoir with brake fluid.

      Fluid
      SAE J1703 or FMVSS No. 116 DOT 3

      Note

      Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.

  5. BLEED MASTER CYLINDER

    Tech Tips

    If the master cylinder has been disassembled or if the reservoir becomes empty, bleed the air from the master cylinder.


    1. A01CJ3V

      Using a 12 mm union nut wrench, disconnect the 2 brake tubes from the master cylinder.

    2. A01CJDH

      Slowly depress the brake pedal and hold it there (Step A).

    3. A01CI7O

      Block the outer holes with your fingers, and release the brake pedal (Step B).

    4. Repeat step A and B 3 or 4 times.

    5. Using a 12 mm union nut wrench, connect the 2 brake tubes to the master cylinder.

      Torque:
      24 N*m  { 245 kgf*cm, 18 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.

  6. BLEED BRAKE LINE

    A01CIA0

    Note


    • Make sure the vehicle is secured in place and cannot move.

    • Make sure the ignition switch is off before bleeding the brake system.


    1. Connect the vinyl tube to the bleeder plug.

    2. Depress the brake pedal 3 times, and then hold down the brake pedal. (Procedure 1)

    3. Loosen the bleeder plug at least 90° so that brake fluid and air begin to come out, and then tighten the bleeder plug approximately 2 seconds after opening it. (Procedure 2)

    4. Wait 3 seconds after Procedure 2, and then begin depressing the brake pedal again. Repeat Procedures 1 and 2, 10 times or more. (Procedure 3)

      Note

      Even if air does not come out, repeat the procedures 10 times or more.

    5. Repeat Procedure 1 through Procedure 3 above, twice for each wheel, in the following order: Left Front → Left Rear → Right Rear → Right Front → Left Front → Left Rear → Right Rear → Right Front.

    6. Tighten the bleeder plug.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  7. INSPECT FOR BRAKE FLUID LEAK

  8. INSPECT BRAKE PEDAL RESERVE DISTANCE

    Click here

    Note

    If the pedal reserve is low, there may be air remaining in the brake system, so perform a driving test and bleed the brake system again.

  9. CHECK FLUID LEVEL IN RESERVOIR

    A01CHDW

    1. Check the fluid level and add fluid if necessary.

      Fluid
      SAE J1703 or FMVSS No. 116 DOT 3

  10. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH


    1. Connect each connector.

    2. Attach the 5 clips to install the lower instrument panel finish panel sub-assembly.

  11. INSTALL OIL RESERVOIR TANK COVER LH


    1. Engage the 4 claws and 3 guides to install the oil reservoir tank cover LH.

  12. INSTALL UPPER STEERING COLUMN COVER


    1. Engage the 3 claws and install the steering column cover plate.

    2. Install the upper steering column cover onto the steering column.

  13. INSTALL LOWER STEERING COLUMN COVER


    1. Engage the 4 claws and install the lower steering column cover.

    2. Install the 5 screws.

  14. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL


    1. Connect each connector.

    2. Attach the 3 clips to install the lower instrument panel finish panel sub-assembly LH.

    3. Install the 2 clips.