BRAKE MASTER CYLINDER (for LHD) INSTALLATION

Note

While the battery is connected, even if the engine switch is off, the brake control system activates when the brake pedal is depressed or the door courtesy switch turns on. Therefore during servicing of the brake system components, do not operate the brake pedal and open/close the doors while the battery is connected.


  1. INSTALL BRAKE BOOSTER GASKET


    1. A01GMEM

      Install a new brake booster gasket to the brake master cylinder with simulator.

  2. INSTALL BRAKE MASTER CYLINDER WITH SIMULATOR ASSEMBLY


    1. A01GK86

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

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

    2. Connect the brake stroke simulator connector.

  3. INSTALL PUSH ROD PIN


    1. A01GKXJE02
      Text in Illustration
      *1 Push Rod Pin
      *2 Clip
      *3 Push Rod Clevis
      *4 Lithium soap base glycol grease

      Apply lithium soap base glycol grease to the push rod pin.

    2. Set the master cylinder push rod clevis in place, insert the push rod pin from outside of the vehicle and then install a new clip.

  4. INSTALL BRAKE PEDAL RETURN SPRING


    1. Install the spring between the pedal and steering column.

  5. INSTALL RESERVOIR BRACKET


    1. A01GNJV

      Install the reservoir bracket with the 3 bolts.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  6. INSTALL NO. 1 RESERVOIR HOSE


    1. A01GMYZE02
      A01GK9DE02

      Install the reservoir connector (labeled A) to the No. 1 reservoir hose (labeled B) with the hose clip (labeled C) as shown in the illustration.

      Length "A"
      4.0 to 7.0 mm (0.158 to 0.276 in.)
      Text in Illustration
      *1 Reservoir Connector
      *a View B
      *b Paint Mark
      *c 75° to 105°
      *d 30° to 60°

    2. With the paint mark on the hose's tip facing the top of the vehicle, install the No. 1 reservoir hose (labeled B) to the master cylinder with the hose clip (labeled D).

      Tech Tips

      Install the hose clip so that its claws face the top of the vehicle.

  7. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY


    1. A01GL41E02

      Connect the No. 1 reservoir hose (labeled F) and No. 2 brake actuator hose (labeled E) to the reservoir. The reservoir connector connecting procedure must be followed as described below:


      1. Remove the foreign matter entry prevention plastic bags.

        Note

        Check that there is no damage or foreign objects on the connected part of the reservoir and reservoir connectors.

      2. A01GJXUE02
        Text in Illustration
        *1 Reservoir
        *2 Rib

        Insert the reservoir connector to the reservoir until the reservoir connector makes a "click" sound, so that the reservoir connector tip's groove is aligned with the reservoir's rib.

      3. A01GII2E02
        Text in Illustration
        *1 Claw
        *2 Lock

        Securely set the lock of the reservoir connector.

      4. Check that the reservoir connector lock's claw is securely attached.

    2. With the paint mark on the hose's tip facing the top of the vehicle, connect the No. 1 brake actuator hose (labeled D) to the reservoir with the hose clip.

      Tech Tips

      Install the hose clip so that its claws face the top of the vehicle.

    3. Connect the brake fluid level warning switch connector (labeled C), and then attach the connector clamp (labeled B) to the reservoir bracket.

    4. Install the brake fluid reservoir with the 2 bolts.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

    5. Connect the wire harness clamp (labeled A) to the reservoir.

  8. INSTALL BRAKE ACTUATOR AND BRAKE ACCUMULATOR PUMP ASSEMBLY

    Click here

  9. CONNECT NO. 3 RELAY BLOCK


    1. A01GJF2

      Install the No. 3 relay block to the reservoir bracket.

      Note

      Check that the claw of the No. 3 relay block is securely attached to the reservoir bracket.

  10. INSTALL SKID CONTROL ECU BRACKET

    Click here

  11. INSTALL SKID CONTROL ECU

    Click here

  12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note


    • Make sure that the 2 accumulator pump connectors are disconnected.

    • When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  13. CONNECT BRAKE ACCUMULATOR PUMP CONNECTORS


    1. Add brake fluid into the reservoir between MAX and MIN line on the brake fluid reservoir.

      Brake fluid
      SAE J1703 or FMVSS No. 116 DOT3
    2. A01GL4Y

      With the power switch off, connect the 2 brake accumulator pump connectors.

    3. Turn the power switch on (IG) and check that the brake accumulator pump motor operates and stops.

    4. Turn the power switch off.

  14. BLEED BRAKE MASTER CYLINDER


    1. Bleed brake master cylinder.


      1. Remove the brake master cylinder reservoir filler cap assembly.

      2. Add brake fluid into the reservoir between MAX and MIN level on the brake fluid reservoir.

        Brake fluid
        SAE J1703 or FMVSS No. 116 DOT3

      3. Connect the intelligent tester to the DLC3 and turn the power switch on (IG).

      4. Turn the intelligent tester on and enter the following menus: Chassis / ABS/VSC/TRC / Utility / Air Bleeding.

      5. Select the "Master Cylinder or Stroke Simulator has been removed" and bleed brake master cylinder according to the intelligent tester display.

      6. After air bleeding, tighten each bleeder plug.

        Torque:
        for Front Brake (except 6-pot caliper)
        11 N*m  { 110 kgf*cm, 8 ft.*lbf }
        for Front Brake (6-pot caliper)
        19 N*m  { 194 kgf*cm, 14 ft.*lbf }
        for Rear Brake
        11 N*m  { 110 kgf*cm, 8 ft.*lbf }

    2. Clear the DTCs Click here.

    3. Turn the intelligent tester off and turn the power switch off.

    4. Inspect for brake fluid leaks.

    5. Adjust the brake fluid level in the reservoir Click here.

  15. CHECK AND ADJUST BRAKE PEDAL

    Click here

  16. INSTALL NO. 1 INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY

    Click here

  17. INSTALL FRONT WHEEL

    Torque:
    140 N*m  { 1428 kgf*cm, 103 ft.*lbf }

  18. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  19. INSTALL COWL TOP VENTILATOR LOUVER RH


    1. A01GM4S

      Install the 6 clips and cowl top ventilator louver RH.

      Note

      Be sure to install the cowl top ventilator louver RH properly. If it is not installed properly, water may enter the engine room and cause malfunctions.

  20. INSTALL V-BANK COVER SUB-ASSEMBLY


    1. A01GMKRE01

      Slide the cover from the vehicle front toward the rear of the vehicle to attach the 2 clips labeled A, and then attach the 4 clips labeled B to install the V bank cover sub-assembly.

      Note


      • Make sure the clips are attached securely.

      • Attaching the clips forcefully or hitting the top of the clips may damage them.

      • When attaching the clips labeled A, be sure to slide the cover from the front of the vehicle toward the rear of the vehicle.

  21. CLEAR DTC

    Click here

  22. PERFORM LINEAR VALVE OFFSET LEARNING


    1. When the brake master cylinder with simulator assembly is replaced, perform the linear valve offset learning Click here.

  23. CHECK BRAKE ACTUATOR WITH TESTER


    1. Check the brake actuator and pressure sensor Click here.

  24. CHECK BRAKE MASTER CYLINDER WITH TESTER


    1. Check the brake master cylinder and stroke simulator Click here.

  25. CHECK SRS WARNING LIGHT

    Click here

  26. CHECK MASTER CYLINDER PRESSURE SENSOR SIGNAL


    1. Check the pressure sensor signal Click here.

  27. CHECK FOR DTC


    1. If any DTC is set, perform the troubleshooting for that DTC Click here.

  28. READ VALUE OF ACCUMULATOR PRESSURE SENSOR OUTPUT VOLTAGE

    Tech Tips

    If removing and installing the No. 3 brake actuator tube, check for a brake fluid leak from the No. 3 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. 3 tube connection area is difficult.


    1. Turn the engine switch off.

    2. Connect the intelligent tester to the DLC3.

    3. Turn the engine switch on (IG).

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

      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. A01GN4G

      Depress the brake pedal 4 or 5 times to operate the pump motor, and check the output value on the intelligent tester 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. 3 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. 3 brake actuator 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.