BRAKE MASTER CYLINDER INSTALLATION


  1. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

    Note

    When install a new brake master cylinder sub-assembly, remove the protectors from the piston and outlet ports.


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

    2. A01EM3TE01

      Apply a light layer of lithium soap base glycol grease to the entire circumference of the brake master cylinder sub-assembly and inner surface of the brake booster assembly as shown in the illustration.

    3. A01ELMX

      Install the brake master cylinder sub-assembly and front brake tube way with the 2 nuts.

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

      Note


      • Do not kink or damage the brake line.

      • Do not allow brake line to twist and interfere with other parts or body during flexible hose tightening.

      • Do not allow any foreign matter such as dirt or dust to enter the brake line.

    4. A01EJEV

      Using a union nut wrench, connect the 2 brake lines and install the No. 1 front brake tube to the brake master cylinder sub-assembly.

      Torque:
      20 N*m  { 199 kgf*cm, 14 ft.*lbf }

      Note


      • Do not kink or damage the brake line.

      • Do not allow brake line to twist and interfere with other parts or body during flexible hose tightening.

      • Do not allow any foreign matter such as dirt or dust to enter the brake line.

      • Use the formula to calculate special torque values for situations where union nut wrench is combined with a torque wrench Click here.

    5. A01EL8X

      Using a union nut wrench, connect the 2 brake lines to the front brake tube way.

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

      Note


      • Do not kink or damage the brake line.

      • Do not allow brake line to twist and interfere with other parts or body during flexible hose tightening.

      • Do not allow any foreign matter such as dirt or dust to enter the brake line.

      • Use the formula to calculate special torque values for situations where union nut wrench is combined with a torque wrench Click here.

    6. A01EJV4

      Connect the connector and engage the clamp.

  2. FILL RESERVOIR WITH BRAKE FLUID


    1. A01EJ3G

      Remove the brake master cylinder reservoir filler cap.

    2. Fill the reservoir with brake fluid.

      Brake Fluid
      SAE J1703 or FMVSS No. 116 DOT 3

      Note


      • Make sure that there is sufficient brake fluid in the reservoir.

      • Do not remove the filter from the brake master cylinder reservoir and be sure to fill with new brake fluid to avoid any potential contamination of the brake system. Contamination, for example by dirt particles or mineral oil, could lead to functional brake problem.

  3. BLEED BRAKE MASTER CYLINDER

    Note


    • To prevent brake fluid from damaging painted surfaces, cover any surrounding parts with a piece of cloth.

    • Be sure to clean your hands before bleeding from master cylinder to avoid any potential contamination of the brake system. Contamination, for example by dirt particles or mineral oil, could lead to functional brake problem.

    Tech Tips

    If the master cylinder is reinstalled or runs out of brake fluid, bleed the master cylinder.


    1. A01EL46

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

    2. A01ELBP

      Slowly depress the brake pedal and hold it down.

    3. A01EM39

      Cover the 2 tube holes with your fingers and release the brake pedal.

    4. Uncover the holes, slowly depress the brake pedal and hold it down. While holding down the brake pedal, cover the tube holes again. Repeat this step 3 or 4 times.

    5. A01EL46

      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


      • Do not bend or damage the brake lines.

      • Do not allow brake line to twist and interfere with other parts or body during tightening.

      • Do not allow any foreign matter such as dirt or dust to enter the brake line.

      • Use the formula to calculate special torque values for situations where union nut wrench is combined with a torque wrench Click here.

  4. BLEED BRAKE LINE

    Note

    Bleed the brake line of the wheel farthest from the master cylinder first.


    1. Connect a vinyl tube to the bleeder plug.

    2. Depress the brake pedal several times, and while holding down the brake pedal, loosen the bleeder plug*1.

    3. When fluid stops coming out, tighten the bleeder plug and release the brake pedal*2.

    4. Repeat steps *1 and *2 until all the air in the brake fluid is completely bled out and the new brake fluid comes out.

    5. Tighten the bleeder plug completely.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

    6. Repeat the above steps to replace the brake fluid of the brake lines for each wheel.

  5. INSPECT FOR BRAKE FLUID LEAK

  6. INSPECT FLUID LEVEL IN RESERVOIR


    1. A01EKWYE01
      Text in Illustration
      *1 MAX Line
      *2 MIN Line

      Check the fluid level.

      Tech Tips

      If brake fluid level is lower than the MIN line, check for leaks and inspect the disc brake pads. If necessary, refill the reservoir with brake fluid to the MAX line after repair or replacement.

      Brake Fluid
      SAE J1703 or FMVSS No. 116 DOT 3

  7. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  8. INSTALL AIR CLEANER CAP SUB-ASSEMBLY


    1. A01EKRC

      Connect the air-cleaner cap sub-assembly to the throttle body assembly and lock the hose band.

    2. A01EJ98

      Install the air cleaner cap sub-assembly with the 2 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
    3. A01EKWW

      Connect the ventilation hose to the cylinder head cover.

    4. A01EKFY

      Connect the mass air flow meter connector and install the wire harness clamp to the air cleaner cap.

    5. Install the hose to the hose clamp.