BRAKE MASTER CYLINDER INSTALLATION


  1. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD

    Note

    Adjust the brake booster assembly without vacuum. (Depress the brake pedal several times with engine stopped.)

    Tech Tips

    Adjustment of the brake booster push rod is performed when the brake master cylinder sub-assembly is replaced with a new one. The adjustment is not necessary when the brake booster assembly is replaced with a new one, but the brake master cylinder sub-assembly is reinstalled.


    1. A003F3PE07
      Text in Illustration
      *1 Accessory Tool
      *a Apply Chalk

      Apply chalk to the tip of the accessory tool.

      Tech Tips

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

    2. Place the accessory tool on the brake booster assembly.

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

      Clearance
      0 mm (0 in.)

      Tech Tips


        Adjust the clearance in the following cases:

      • If there is clearance between the accessory tool and the shell of the brake booster (floating accessory tool), the clearance is too small.

      • If the chalk does not stick to the tip of the brake booster push rod, the clearance is too large.

    4. A003CBAE01

      If clearance is not within the specified range, fix the push rod using SST and adjust the length of the protruding adjusting bolt.

      SST
      09737-00020

      Tech Tips

      When adjusting the push rod, depress the brake pedal sufficiently so that the push rod sticks out.

  2. INSTALL BRAKE MASTER CYLINDER


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

    2. for 1KD-FTV, 2KD-FTV and 5L-E:


      1. Install the brake master cylinder and bracket to the booster with the 2 nuts.

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

        Note

        Check that the stopper of the harness clamp bracket is securely holding on the brake master cylinder assembly.

    3. for 1TR-FE, 2TR-FE:


      1. Install the brake master cylinder to the brake booster with the 2 nuts.

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

    4. for Manual Transmission:


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

    5. w/o VSC:


      1. A003COCE05
        Text in Illustration
        *a Torque Wrench Fulcrum Length

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

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

        Tech Tips


        • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.

        • When using a union nut wrench (fulcrum length of 22 mm (0.8661 in.)) + torque wrench (fulcrum length of 162 mm (6.3779 in.)): 13 N*m (137 kgf*cm, 10 ft.*lbf)

    6. w/ VSC:


      1. A003COCE05
        Text in Illustration
        *a Torque Wrench Fulcrum Length

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

        Torque:
        Specified tightening torque
        25 N*m  { 255 kgf*cm, 18 ft.*lbf }

        Tech Tips


        • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.

        • When using a union nut wrench (fulcrum length of 20 mm (0.7874 in.)) + torque wrench (fulcrum length of 180 mm (7.0866 in.)): 23 N*m (229 kgf*cm, 17 ft.*lbf)

    7. Connect the level warning light switch connector.

    8. Attach the brake fluid level warning switch connector clamp.

  3. ADD BRAKE FLUID

    Fluid
    SAE J1703 or FMVSS No. 116 DOT3 or equivalent

    Note

    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 problems.

  4. BLEED BRAKE MASTER CYLINDER

    Tech Tips

    If the master cylinder has been disassembled or if the reservoir becomes empty, bleed the air from the master cylinder.


    1. A003B4W

      Using a union nut wrench, disconnect the brake lines from the master cylinder.

    2. Slowly depress the brake pedal and hold it there.

    3. A003AVB

      Block the outer holes with your fingers, and release the brake pedal.

    4. Remove your fingers. Slowly depress the brake pedal and hold it again. Block the outer holes with your fingers and release the brake pedal. Repeat this procedure 3 or 4 times.

    5. A003COCE01
      Text in Illustration
      *a Torque Wrench Fulcrum Length

      Using a union nut wrench, connect the brake lines to the master cylinder.

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

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.

      • When using a union nut wrench (fulcrum length of 22 mm (0.8661 in.)) + torque wrench (fulcrum length of 162 mm (6.3779 in.)): 13 N*m (137 kgf*cm, 10 ft.*lbf)

  5. BLEED BRAKE LINE


    1. Connect the vinyl tube to the bleeder plug.

    2. Depress the brake pedal several times and loosen the bleeder plug with the pedal held down.

    3. At the point where the fluid stops coming out, tighten the bleeder plug and release the brake pedal.

    4. Repeat this procedure until the air in the brake fluid is completely bled out.

    5. Tighten the bleeder plug.


      1. Front bleeder plug:

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

      2. Rear bleeder plug:

        Torque:
        11 N*m  { 112 kgf*cm, 8 ft.*lbf }

    6. Repeat the above procedure to bleed the air out of the brake line for each wheel.

  6. CHECK BRAKE FLUID LEVEL


    1. Check the fluid level and add fluid if necessary.

      Fluid
      SAE J1703 or FMVSS No.116 DOT3 or equivalent

      Note

      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 problems.

  7. CHECK BRAKE FLUID LEAKAGE