BRAKE MASTER CYLINDER INSTALLATION

PROCEDURE


  1. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY


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

    2. A0057C0E02
      Text in Illustration
      *1 Piston

      Install the brake master cylinder with the 2 nuts.

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

      Note


      • The master cylinder requires careful handling. Do not allow the master cylinder to receive any impact, such as from being dropped. Do not reuse a master cylinder that has been dropped.

      • Do not strike or pinch the master cylinder piston, and do not cause any damage to the master cylinder piston by any other means.

      • When installing the master cylinder to the brake booster, or when removing the master cylinder from the brake booster, make sure that the master cylinder is kept horizontal or with its tip facing downward (the piston faces upward) to prevent the master cylinder piston from falling out.

      • Do not allow any foreign objects to contaminate the master cylinder piston. If a foreign object gets on the piston, remove it by using a piece of cloth and then apply an even layer of lithium soap base glycol grease around the circumference (sliding part) of the piston.

      • Do not use any other type of grease or fluid.

    3. A0057KWE06
      Text in Illustration
      *A for LHD
      *B for RHD

      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. A005586E03
      Text in Illustration
      *A for LHD
      *B for RHD

      Attach the clamp and connect the connector.

  2. CONNECT CLUTCH TUBE (for Manual Transaxle)


    1. A0054MSE03
      Text in Illustration
      *A for LHD
      *B for RHD

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

  3. INSTALL BRAKE ACTUATOR ASSEMBLY


    1. Install the brake actuator assembly Click here.

  4. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for 1ZR-FAE)

    Click here

  5. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for 2ZR-FAE)

    Click here

  6. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for 3ZR-FE)

    Click here

  7. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for 3ZR-FAE)

    Click here

  8. INSTALL WINDSHIELD WIPER MOTOR AND LINK


    1. Install the windshield wiper motor and link Click here.

  9. INSTALL NO. 2 CYLINDER HEAD COVER (for 1ZR-FAE)

    Click here

  10. INSTALL NO. 2 CYLINDER HEAD COVER (for 2ZR-FAE)

    Click here

  11. INSTALL NO. 2 CYLINDER HEAD COVER (for 3ZR-FE)

    Click here

  12. INSTALL NO. 2 CYLINDER HEAD COVER (for 3ZR-FAE)

    Click here

  13. FILL RESERVOIR WITH BRAKE FLUID

    Click here

  14. BLEED BRAKE MASTER CYLINDER

    Click here

  15. BLEED BRAKE LINE

    Click here

  16. BLEED CLUTCH LINE (for EC60)

    Click here

  17. INSPECT FOR BRAKE FLUID LEAK

  18. INSPECT BRAKE FLUID LEVEL IN RESERVOIR

    Click here