BRAKE MASTER CYLINDER INSTALLATION

Note

Do not hold the piston when handling the master cylinder sub-assembly, as the piston may come out of the master cylinder sub-assembly.


  1. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY (for LHD)


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

    2. Install the brake master cylinder sub-assembly to the brake booster assembly with the 2 nuts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    3. Using a union nut wrench 10 mm, install the 2 brake tubes to the brake master cylinder sub-assembly (w/o VSC).

      Torque:
      15 N*m  { 155 kgf*cm, 11 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. Using a union nut wrench 12 mm, install the 2 brake tubes to the brake master cylinder sub-assembly (w/ VSC).

      Torque:
      20 N*m  { 199 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.

    5. Connect the brake fluid level warning switch connector.

  2. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY (for RHD)


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

    2. Install the brake master cylinder sub-assembly to the brake booster assembly with the 2 nuts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    3. Install the brake tube clamp to the body.

    4. Using a union nut wrench 10 mm, install the No. 3 brake tube.

      Torque:
      15 N*m  { 155 kgf*cm, 11 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.

      • Make sure that the grommet is installed correctly

    5. Using a union nut wrench 10 mm, install the 2 brake tubes to the brake master cylinder sub-assembly (w/o VSC).

      Torque:
      15 N*m  { 155 kgf*cm, 11 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. Using a union nut wrench 12 mm, install the 2 brake tubes to the brake master cylinder sub-assembly (w/ VSC).

      Torque:
      20 N*m  { 199 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.

    7. Connect the brake fluid level warning switch connector.

  3. INSTALL ENGINE ROOM RELAY BLOCK (for LHD)


    1. Engage the 3 wire harness clamps.

    2. A0138XKE01

      Engage the claw and install the engine room relay block.

    3. Install the 2 bolts.

      Torque:
      Bolt A
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
      Bolt B
      8.4 N*m  { 85 kgf*cm, 74 in.*lbf }

  4. INSTALL BATTERY (for LHD)

    A0136B5E01
    Text in Illustration
    *a Identification line
    *b A-A
    *c B-B

    1. Install the battery onto the battery clamp sub-assembly, as shown in the illustration.

      Note


      • The identification line should be seen after installing the battery.

      • The battery clamp should be in contact with the battery after the installation.

    2. Install the battery clamp with the bolt.

      Torque:
      15 N*m  { 154 kgf*cm, 11 ft.*lbf }

    3. Connect the battery positive (+) terminal with the nut.

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

  5. FILL RESERVOIR WITH BRAKE FLUID

    Fluid
    SAE J1704 or FMVSS No. 116 DOT4

  6. BLEED BRAKE 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. A0135Y5

      Using a 10 mm union nut wrench, separate the brake tubes from the master cylinder (w/o VSC).

    2. Using a 12 mm union nut wrench, separate the brake tubes from the master cylinder (w/ VSC).

    3. A0137VF

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

    4. A0138P2

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

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

    6. A01385EE01

      Using a 10 mm union nut wrench, install the brake tubes to the master cylinder (w/o VSC).

      Torque:
      without 10 mm union nut wrench
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }
      with 10 mm union nut wrench
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }

      Note


      • This torque value can be obtained by using a torque wrench with a fulcrum length of 300 mm (11.8 in.) and a 10 mm union nut wrench with a fulcrum length of 22 mm (0.886 in.) Click here.

      • This torque value is effective when the union nut wrench is parallel to a torque wrench.

    7. Using a 12 mm union nut wrench, install the brake tubes to the master cylinder (w/ VSC).

      Torque:
      without 12 mm union nut wrench
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      with 12 mm union nut wrench
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

      Note


      • This torque value can be obtained by using a torque wrench with a fulcrum length of 300 mm (11.8 in.) and a 12 mm union nut wrench with a fulcrum length of 30 mm (1.18 in.) Click here.

      • This torque value is effective when the union nut wrench is parallel to a torque wrench.

  7. BLEED BRAKE LINE

    A0137E0

    1. Connect a vinyl tube to the bleeder plug.

    2. Depress the brake pedal several times, then loosen the bleeder plug with the pedal depressed (Step C).

    3. At the point where the fluid stops coming out, tighten the bleeder plug, then release the brake pedal (Step D).

    4. Repeat step C and D until all the air in the fluid is completely bled out.

    5. Tighten the bleeder plug.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

    6. Repeat the above procedure to bleed the air out of the brake line for each wheel.

  8. CHECK FLUID LEVEL IN RESERVOIR


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

      Fluid
      SAE J1704 or FMVSS No. 116 DOT4

  9. INSTALL COWL TOP PANEL OUTER


    1. Install the cowl top panel outer with the 10 bolts.

      Torque:
      9.2 N*m  { 94 kgf*cm, 81 in.*lbf }

    2. Engage the grommet and install the wire harness.

    3. Engage the wire harness clamp.

  10. INSTALL FRONT NO. 1 VENTILATOR SEAL


    1. Install the No. 1 ventilator seal with the 2 clips.

  11. INSTALL FRONT AIR SHUTTER SEAL RH


    1. Install the front air shutter seal RH the 2 clips.

  12. INSTALL FRONT WIPER MOTOR AND LINK ASSEMBLY

    Click here

  13. INSTALL FRONT WHEEL (for RHD)

    Torque:
    103 N*m  { 1050 kgf*cm, 76 ft.*lbf }

  14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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

  15. INSPECT FOR BRAKE FLUID LEAK