BRAKE MASTER CYLINDER INSTALLATION


  1. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD

    Note

    Make an adjustment with no vacuum in the brake booster assembly. (Depress the brake pedal several times with the engine stopped.)

    Tech Tips


    • Adjustment of the brake booster push rod is required when the brake master cylinder sub-assembly is replaced with a new one.


    • Adjustment is not necessary when the removed brake master cylinder sub-assembly is reused and the brake booster assembly is replaced with a new one.


    1. Apply chalk to the tip of the accessory tool.

      Tech Tips

      An accessory tool is enclosed with a new brake master cylinder sub-assembly.

    2. A0161XCE01

      Place the accessory tool on the brake booster assembly.

    3. Measure the clearance between the brake booster push rod and accessory tool.

      Standard clearance
      0 mm (0 in.)

      Tech Tips

      Adjust the clearance in the following cases:


      • If there is a clearance between the accessory tool and the shell of the brake booster (floating accessory tool), the push rod is protruding too far.

      • If the chalk does not stick on the tip of the brake booster push rod, the push rod protrusion is insufficient.

    4. A0160UOE01

      If the clearance is not as specified, adjust the push rod length by holding the rod using SST and turning the tip of the rod using a socket driver (7 mm, 0.28 in.).

      SST
      09737-00020

      Tech Tips

      Check the push rod clearance again after adjustment.

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


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

    2. A0163D6

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

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    3. A015ZCPE01
      Text in Illustration
      *a Fulcrum Length

      Using a union nut wrench (10 mm), connect the 2 brake lines to the brake master cylinder sub-assembly.

      Torque:
      without a union nut wrench
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }
      with a union nut wrench
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }

      Note


      • Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).

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

    4. A015ZEG

      Engage the clamp and connect the connector.

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


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

    2. A015ZUX

      Install the brake master cylinder sub-assembly and wire harness clamp bracket to the booster assembly with the 2 nuts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    3. A0163KLE02
      Text in Illustration
      *a Fulcrum Length

      Using a union nut wrench (10 mm), connect the 2 brake lines to the brake master cylinder sub-assembly.

      Torque:
      without a union nut wrench
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }
      with a union nut wrench
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }

      Note


      • Use a torque wrench with a fulcrum length of 250 mm (9.84 in.)

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

    4. A015YUC

      Engage the clamp and connect the connector.

  4. INSTALL NO. 3 ENGINE ROOM RELAY BLOCK (for LHD)


    1. A0163BG

      Install the No. 3 engine room relay block with the bolt and nut.

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

  5. INSTALL NO. 3 ENGINE ROOM RELAY BLOCK (for RHD)


    1. A01613O

      Install the No. 3 engine room relay block with the bolt and nut.

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

  6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  7. BLEED BRAKE SYSTEM

    Tech Tips

    Click here

  8. INSTALL ENGINE ROOM SIDE COVER LH (for LHD)


    1. A016120

      Install the engine room side cover LH with the 5 clips.

  9. INSTALL ENGINE ROOM SIDE COVER RH (for RHD)


    1. A015YK3

      Install the engine room side cover RH with the 4 clips.

  10. INSTALL COOL AIR INTAKE DUCT SEAL


    1. A01638L

      Install the cool air intake duct seal with the 9 clips.