BRAKE MASTER CYLINDER(for LHD) INSTALLATION

CAUTION / NOTICE / HINT

Note

While the battery is connected, even if the engine switch is off, the brake control system activates when the brake pedal is depressed or the door courtesy switch turns on. Therefore during servicing of the brake system components, do not operate the brake pedal and open/close the doors while the battery is connected.

PROCEDURE


  1. INSTALL BRAKE BOOSTER GASKET


    1. A001CX0

      Install a new brake booster gasket to the brake master cylinder with simulator.

  2. INSTALL BRAKE MASTER CYLINDER WITH SIMULATOR ASSEMBLY


    1. A0018UV

      Install the brake master cylinder with simulator with the 4 nuts.

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

    2. Connect the brake stroke simulator connector.

  3. INSTALL PUSH ROD PIN

    Click here

  4. INSTALL BRAKE PEDAL RETURN SPRING

    Click here

  5. INSTALL RESERVOIR BRACKET


    1. A001AUF

      Install the reservoir bracket with the 3 bolts.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  6. INSTALL NO. 1 RESERVOIR HOSE


    1. A001ENSE02
      A0019NUE01

      Install the reservoir connector (labeled A) to the No. 1 reservoir hose (labeled B) with the hose clip (labeled C) as shown in the illustration.

      Length "A"
      4.0 to 7.0 mm (0.158 to 0.276 in.)
      Text in Illustration
      *1 Reservoir Connector
      *a View B
      *b Paint Mark
      *c 75° to 105°
      *d 30° to 60°

    2. With the paint mark on the hose's tip facing the top of the vehicle, install the No. 1 reservoir hose (labeled B) to the master cylinder with the hose clip (labeled D).

      Tech Tips

      Install the hose clip so that its claws face the top of the vehicle.

  7. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY


    1. A0019AUE02

      Connect the No. 1 reservoir hose (labeled F) and No. 2 brake actuator hose (labeled E) to the reservoir. The reservoir connector connecting procedure must be followed as described below:


      1. Remove the foreign matter entry prevention plastic bags.

        Note

        Check that there is no damage or foreign objects on the connected part of the reservoir and reservoir connectors.

      2. A001AYUE03
        Text in Illustration
        *1 Reservoir
        *2 Rib

        Insert the reservoir connector to the reservoir until the reservoir connector makes a "click" sound, so that the reservoir connector tip's groove is aligned with the reservoir's rib.

      3. A001CTRE03
        Text in Illustration
        *1 Claw
        *2 Lock

        Securely set the lock of the reservoir connector.

      4. Check that the reservoir connector lock's claw is securely attached.

    2. With the paint mark on the hose's tip facing the top of the vehicle, connect the No. 1 brake actuator hose (labeled D) to the reservoir with the hose clip.

      Tech Tips

      Install the hose clip so that its claws face the top of the vehicle.

    3. Connect the brake fluid level warning switch connector (labeled C), and then attach the connector clamp (labeled B) to the reservoir bracket.

    4. Install the brake fluid reservoir with the 2 bolts.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

    5. Connect the wire harness clamp (labeled A) to the reservoir.

  8. INSTALL BRAKE ACTUATOR AND BRAKE ACCUMULATOR PUMP ASSEMBLY

    Click here

  9. CONNECT NO. 3 RELAY BLOCK

    Click here

  10. INSTALL SKID CONTROL ECU BRACKET

    Click here

  11. INSTALL SKID CONTROL ECU

    Click here

  12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note


    • Make sure that the 2 accumulator pump connectors are disconnected.

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

  13. CONNECT BRAKE ACCUMULATOR PUMP CONNECTORS


    1. Add brake fluid into the reservoir between MAX and MIN line on the brake fluid reservoir.

      Brake fluid
      SAE J1703 or FMVSS No. 116 DOT3
    2. A001B11

      With the power switch off, connect the 2 brake accumulator pump connectors.

    3. Turn the power switch on (IG) and check that the brake accumulator pump motor operates and stops.

    4. Turn the power switch off.

  14. BLEED BRAKE MASTER CYLINDER

    Click here

  15. CHECK AND ADJUST BRAKE PEDAL

    Click here

  16. INSTALL NO. 1 INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY

    Click here

  17. INSTALL FRONT WHEEL

    Torque:
    140 N*m  { 1428 kgf*cm, 103 ft.*lbf }

  18. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  19. INSTALL COWL TOP VENTILATOR LOUVER RH

    Click here

  20. INSTALL V-BANK COVER SUB-ASSEMBLY

    Click here

  21. CLEAR DTC

    Click here

  22. PERFORM LINEAR VALVE OFFSET LEARNING


    1. When the brake master cylinder with simulator assembly is replaced, perform the linear valve offset learning Click here.

  23. CHECK BRAKE ACTUATOR WITH TESTER


    1. Check the brake actuator and pressure sensor Click here.

  24. CHECK BRAKE MASTER CYLINDER WITH TESTER


    1. Check the brake master cylinder and stroke simulator Click here.

  25. CHECK SRS WARNING LIGHT

    Click here

  26. CHECK MASTER CYLINDER PRESSURE SENSOR SIGNAL


    1. Check the pressure sensor signal Click here.

  27. CHECK FOR DTC


    1. If any DTC is set, perform the troubleshooting for that DTC Click here.

  28. READ VALUE OF ACCUMULATOR PRESSURE SENSOR OUTPUT VOLTAGE

    Click here