BRAKE MASTER CYLINDER INSTALLATION

Tech Tips


  • Use the same procedure for RHD and LHD vehicles.

  • The procedure listed below is for LHD vehicles.


  1. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY


    1. for LHD:


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

      2. Install the brake master cylinder with 2 nuts.

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

      3. Using a union nut wrench, connect the 2 brake lines to the brake master cylinder sub-assembly.

        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.

      4. Attach the clamp and connect the connector.

    2. for RHD:


      1. A01DS5B

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

      2. Install the brake master cylinder and new clamp to the brake booster with 2 nuts.

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

      3. Using a union nut wrench, connect the 2 brake lines to the brake master cylinder sub-assembly.

        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.

      4. Connect the connector.

  2. CONNECT CLUTCH TUBE (for Manual Transmission)


    1. Connect the clutch tube to the brake master cylinder reservoir assembly with the clip.

  3. INSTALL BRAKE ACTUATOR ASSEMBLY (for RHD)


    1. Install the brake actuator sub-assembly Click here.

  4. INSTALL AIR CLEANER CASE (for 2TR-FE RHD)


    1. Install the air cleaner case Click here.

  5. INSTALL AIR CLEANER CASE ASSEMBLY (for 5L-E RHD)


    1. Install the air cleaner case assembly Click here.

  6. BLEED BRAKE SYSTEM

    CAUTION:

    If air is bled without using the intelligent tester, damage or accidents may result. Therefore, always use the intelligent tester when bleeding air.


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

    2. Add brake fluid until the fluid level is between the MIN and MAX lines of the reservoir.

    3. Using a union nut wrench, disconnect the 2 brake tube from the master cylinder.

    4. Slowly depress and hold the brake pedal.

    5. Block the tube holes with your fingers, and then release the brake pedal.

    6. Remove your fingers, slowly depress and hold the brake pedal, block the tube holes with your fingers again, and then release the brake pedal. Repeat this step 3 or 4 times.

    7. Using a union nut wrench, connect the 2 brake tubes to the brake master cylinder assembly.

      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.

    8. Loosen the bleeder plug of the front brake cylinder RH.

    9. Repeatedly depress the brake pedal and bleed the air from the bleeder plug of the front brake cylinder RH.

      Note

      Add fluid as necessary so that the fluid in reservoir does not decrease below the MIN level.

    10. After air is completely bled out, tighten the bleeder plug while depressing the brake pedal.

      Torque:
      11 N*m  { 110 kgf*cm, 8 ft.*lbf }

    11. Bleed the air from the bleeder plug of the front disc brake cylinder LH using the same procedure as for the RH side.

    12. Loosen the bleeder plug of the rear brake cylinder RH.

    13. Repeatedly depress the brake pedal and bleed the air from the bleeder plug of the rear brake cylinder RH.

      Note

      Add fluid as necessary so that the fluid in the reservoir does not decrease below the MIN level.

    14. After the air is completely bled out, tighten the bleeder plug while depressing the brake pedal.

      Torque:
      11 N*m  { 110 kgf*cm, 8 ft.*lbf }

    15. Bleed the air from the bleeder plug of the rear disc brake cylinder LH using the same procedure as for the RH side.

    16. Turn the ignition switch off and connect the intelligent tester to the DLC3.

    17. Turn the ignition switch to on and turn the tester on.

      Note

      Do not start the engine.

    18. Enter the following menus: Chassis / ABS/VSC/TRC / Utility / Air Bleeding.

    19. Select and run "Inhalation" from the Air Bleeding screen on the intelligent tester.

      Note

      Follow the prompts on the tester screen to bleed the air for both wheels (front and rear) on the right side.

    20. Loosen the bleeder plug of the right front wheel.*1

    21. Using the intelligent tester, operate the actuator.

      Tech Tips


      • To protect the actuator, the operation stops automatically.

      • Make sure the brake pedal is released.

    22. Check the intelligent tester screen to confirm that the operation stopped.

    23. Tighten the bleeder plug.*2

    24. Repeat the procedures above from *1 to *2 until the air is completely bled out.

    25. Tighten the bleeder plug.

      Torque:
      11 N*m  { 110 kgf*cm, 8 ft.*lbf }

    26. Bleed the air for the right rear wheel using the same procedure as for the right front wheel.

    27. Select and run "Decrease" from the Air Bleeding screen on the intelligent tester.

      Note

      Follow the prompts on the tester screen to bleed the air for all 4 wheels.

    28. Loosen the bleeder plug of the right front wheel.*3

    29. Using the intelligent tester, operate the actuator and at the same time fully depress and hold the brake pedal.

      Tech Tips

      To protect the solenoids, the actuator operation stops automatically in 4 seconds. When operating the actuator repeatedly, follow the prompts on the tester screen and wait for 20 seconds or more between each operation.

      Note


      • At this time, the brake pedal becomes difficult to depress. However, be sure to hold the brake pedal in the fully depressed position until brake fluid comes out of the bleeder plug.

      • Do not repeatedly depress the brake pedal, hold the brake pedal in the fully depressed position.

    30. Tighten the bleeder plug and release the brake pedal.*4

    31. Repeat the procedures above from *3 to *4 until the air in completely bled out.

    32. Tighten the bleeder plug.

      Torque:
      11 N*m  { 110 kgf*cm, 8 ft.*lbf }

    33. Bleed the air for the other 3 wheels using the same procedure as for the right front wheel.

    34. Repeat the procedure in which air is bled from the brake line by repeatedly depressing the brake pedal.

      Note

      Repeat this step for each wheel until air is completely bled out.

    35. Inspect for brake fluid leaks.

    36. Inspect fluid level in reservoir Click here.

    37. Check and clear the DTCs Click here for VSC).

  7. FILL RESERVOIR WITH BRAKE FLUID

    A01DROBE01
    Text in Illustration
    *A for LHD (2TR-FE, 5L-E)
    *B for LHD (1GR-FE, 1KD-FTV)
    *C for RHD

    1. Fill the reservoir with brake fluid.

      Brake fluid
      SAE J1703 or FMVSS No. 116 DOT 3

  8. BLEED CLUTCH LINE


    1. Remove the bleeder plug cap of the release cylinder.

    2. Connect a vinyl tube to the bleeder plug.

    3. Depress the clutch pedal several times, and then loosen the bleeder plug while the pedal is depressed.

    4. When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.

    5. Repeat the previous 2 steps until all the air in the fluid is completely bled.

    6. Tighten the bleeder plug.

      Torque:
      11 N*m  { 110 kgf*cm, 8 ft.*lbf }

    7. Install the bleeder plug cap.

    8. Check that all the air has been bled from the clutch line.

  9. CHECK FLUID LEVEL IN RESERVOIR


    1. Check the fluid level.

      If the brake fluid level is low, check for leaks and inspect the disc brake pad. If necessary, refill the reservoir with brake fluid after repair or replacement.

      Brake fluid
      SAE J1703 or FMVSS No. 116 DOT 3

  10. CHECK FOR BRAKE FLUID LEAK FROM CLUTCH LINE